CHRYSLER

CORPORATION

SERVICE MANUAL

1994 JEEPT
GRAND CHEROKEE

To order the special service tools used and

illustrated, please refer to the instructions on
inside back cover.

NO PART OF THIS PUBLICATION MAY BE

REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM
OR BY ANY MEANS, ELECTRONIC, ME-
CHANICAL, PHOTOCOPYING, RECORDING,
OR OTHERWISE, WITHOUT THE PRIOR
WRITTEN PERMISSION OF CHRYSLER
CORPORATION.

Chrysler Corporation reserves the right to make changes in design or to

make additions to or improvements in its products without imposing any ob-
ligations upon itself to install them on its products previously manufactured.

Litho in U.S.A. Copyright © 1993 Chrysler Corporation 15M0693

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 FOREWORD

The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. This manual does not cover theory of operation, which is addressed
in service training material. Information describing the operation and use of standard and optional equipment
is included in the Owner’s Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain general information, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the components. To as-
sist in locating a group title page, use the Group Tab Locator on the following page. The solid bar after the
group title is aligned to a solid tab on the first page of each group. The first page of the group has a contents
section that lists major topics within the group. If you are not sure which Group contains the information you
need, look up the Component/System in the alphabetical index located in the rear of this manual.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide Chrysler
Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When re-
placing fasteners, always use the same type (part number) fastener as removed.
Chrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair
methods, or vehicle wiring at any time without prior notice or incurring obligation.

NOTE: The acronyms, terminology and nomenclature used to identify emissions related components in
this manual may have changed from prior publications. These new terms are in compliance with S.A.E.
recommended practice J1930.

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 GROUP TAB LOCATOR

— Introduction

0 Lubrication and Maintenance

2 Front Suspension and Axle

3 Rear Suspension and Axles

5 Brakes

6 Clutch

7 Cooling System

8 Electrical

9 Engines

11 Exhaust System and Intake Manifold

13 Frame and Bumpers

14 Fuel System

16 Propeller Shafts

19 Steering

21 Transmissions and Transfer Cases

22 Wheels and Tires

23 Body Components

24 Heating and Air Conditioning

25 Emission Control Systems

Index

Service Manual Comment Forms (Rear of Manual)

Z INTRODUCTION 1

INTRODUCTION
CONTENTS

page page

DESIGNATIONS, LABELS/PLATES/DECALS, MEASUREMENT AND TORQUE

CODES AND DIMENSIONS/WEIGHTS . . . . . 1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 5

DESIGNATIONS, LABELS/PLATES/DECALS, CODES AND DIMENSIONS/WEIGHTS

INDEX
page page

Body Code Plate . . . . . . . . . . . . . . . . . . . . . . . . .. 1 Vehicle Designation . . . . . . . . . . . . . . . . . . . . . . . . 1

Engine and Transmission/Transfer Case Vehicle Dimension . . . . . . . . . . . . . . . . . . . . . . . . . 3
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Vehicle Identification Number (VIN) Plate . . . . . . . . . 1
International Vehicle Control and Display Symbols . . 4 Vehicle Safety Certification Label . . . . . . . . . . . . . . . 1
Major Component Identification . . . . . . . . . . . . . . . . 2 Vehicle Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trailer Towing Specifications . . . . . . . . . . . . . . . . . . 4

VEHICLE DESIGNATION
The Vehicle Code Designation for Grand Cherokee
vehicles is ZJ. The code is used to identify the vehicle
in charts, captions and in service procedures. The ve-
hicle code is different than the Vehicle Identification
Number (VIN) or the wheelbase/model code.

VEHICLE SAFETY CERTIFICATION LABEL

A certification label is attached to the left side B-
pillar (Fig. 1). The label certifies that the vehicle con-
forms to Federal Motor Vehicle Safety Standards
(FMVSS).The label also lists the:
• 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 Fig. 1 Vehicle Safety Certification Label
• Vehicle Identification Number (VIN)
• Type of vehicle • Equipment Identification Plate
• Type of rear wheels • Vehicle Safety Certification Label
• Bar code • Frame rail
• Month, Day and Hour (MDH) of final assembly
BODY CODE PLATE
VEHICLE IDENTIFICATION NUMBER (VIN) PLATE A metal Body Code plate is attached (riveted) to
The Vehicle Identification Number (VIN) plate is the top, left side of the radiator reinforcement. There
attached to the top left side of the instrument panel. can be a maximum of seven rows of vehicle informa-
The VIN contains 17 characters that provide data tion imprinted on the plate. The information should
concerning the vehicle. Refer to the decoding chart to be read from left to right, starting with line 1 at the
determine the identification of a vehicle. bottom of the plate up to line 7 (as applicable) at the
The Vehicle Identification Number is also im- top of the code plate (Fig.2).
printed on the: Refer to the decoding chart to decode lines 1
• Body Code Plate through 3.
2 INTRODUCTION Z

VEHICLE IDENTIFICATION NUMBER (VIN) DECODING

Lines 4 through 7 on the plate are imprinted in se- When a second body code plate is necessary, the
quence according to the following descriptions: first four spaces on each row will not be used because
• 3-character sales code of the plate overlap.
• 3-digit numerical code
• 6-digit SEC code ENGINE AND TRANSMISSION/TRANSFER CASE
If there is not enough space left in the row for all IDENTIFICATION
of the 6-digit SEC code: Refer to Group 9—Engines for all engine identifica-
tion data.
• The unused space will remain blank
Refer to Group 21—Transmissions for all transmis-
• The code will be listed in the next row.
sion/transfer case identification data.
The last nine positions of row 7 will contain a
2-digit code and a 6-digit serial number. MAJOR COMPONENT IDENTIFICATION
The last code on a body code plate will be followed Refer to the applicable group for identification
by the imprinted word END. When two plates are re- data.
quired, the last available spaces on the first plate
will be imprinted with the letters CTD (for contin-
BODY CODE DECODING
ued).

Fig. 2 Body Code Plate

Z INTRODUCTION 3

VEHICLE DIMENSION VEHICLE WEIGHTS

The Vehicle Dimension chart provides the dimen- The Vehicle Weights chart provides:
sions for each type of Grand Cherokee vehicle. • The Gross Vehicle Weight Rating (GVWR),
• The payload
• The curb weight for each vehicle type/wheelbase
VEHICLE DIMENSIONS

VEHICLE WEIGHTS
4 INTRODUCTION Z

TRAILER TOWING SPECIFICATIONS INTERNATIONAL VEHICLE CONTROL AND DISPLAY

The Trailer Towing Specifications chart provides: SYMBOLS
• The maximum trailer tongue weight The graphic symbols illustrated in the following
• The maximum trailer weight chart are used to identify various instrument con-
• The maximum combined weight of the trailer/load/ trols. The symbols correspond to the controls and dis-
towing vehicle with a specific engine/transmission/ax- plays that are located on the instrument panel.
le combination.

TRAILER TOWING SPECIFICATIONS

INTERNATIONAL CONTROL AND DISPLAY SYMBOLS

Z INTRODUCTION 5

MEASUREMENT AND TORQUE SPECIFICATIONS

INDEX
page page
Metric and English/Sae Conversion . . . . . . . . . . . . . 5 Torque Specifications ....................... 5
Specification Notations . . . . . . . . . . . . . . . . . . . . . . 5

SPECIFICATION NOTATIONS the bolt threads are lubricated and by 20 percent if

new.
WARNING: THE USE OF INCORRECT ATTACHING
HARDWARE CAN RESULT IN COMPONENT DAM- STANDARD TORQUE SPECIFICATIONS
AGE AND/OR PERSONAL INJURY.

It is important to retain the original attaching

hardware for assembly of the components. If the at-
taching hardware is not reusable, hardware with
equivalent specifications must be used.

METRIC AND ENGLISH/SAE CONVERSION

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

TORQUE SPECIFICATIONS
TORQUE CHARTS
A torque chart for fasteners is provided at the end
of each group (of service information). Refer to the
Standard Torque Specifications chart to determine
torque values not listed in the group (Figs. 1 and 2).
It is important to be aware that the torque values
listed in the chart are based on clean and dry bolt
threads. Reduce the torque value by 10 percent when
CONVERSION FORMULAS AND EQUIVALENT VALUES
6 INTRODUCTION Z

BOLT THREAD AND GRADE/CLASS

IDENTIFICATION

THREAD IDENTIFICATION
SAE and metric bolt/nut threads are not the same.
The difference is described in the Thread Notation
chart.
THREAD NOTATION—SAE AND METRIC

GRADE/CLASS IDENTIFICATION
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 Fig. 1 SAE Bolt Grade Identification
line marks on the top of each bolt head (Fig. 1). The greater the bolt strength. Some metric nuts are im-
actual bolt strength grade corresponds to the number printed with a single-digit strength class on the nut
of line marks plus 2. face.
• A grade 2 bolt has no line marks on top of the bolt
head
• A grade 5 bolt has 3 line marks on top of the bolt
head
• A grade 7 bolt has 5 line marks on top of the bolt
head
• A grade 8 bolt has 6 line marks on top of the bolt
head
The most commonly used metric bolt strength
classes are 9.8 and 12.9. The metric strength class Fig. 2 Metric Bolt Class Identification
identification number is imprinted on the head of the METRIC CONVERSION
bolt (Fig. 2). The higher the class number, the Refer to the Metric Conversion chart to convert
torque values listed in metric Newton-meters (Nzm).
Also, use the chart to convert between millimeters
(mm) and inches (in.)
Z INTRODUCTION 7

METRIC CONVERSION
Z LUBRICATION AND MAINTENANCE 0 - 1

LUBRICATION AND MAINTENANCE

CONTENTS

page page

CHASSIS AND BODY . . . . . . . . . . . . . . . . . . . . . 22 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1

DRIVETRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 JUMP STARTING, HOISTING AND TOWING . . . . 8
ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . 12 MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . 5

GENERAL INFORMATION

INDEX
page page

Classification of Lubricants . . . . . . . . . . . . . . . . . . . 2 Lubrication and Replacement Parts

Components Requiring No Lubrication . . . . . . . . . . . 3 Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 2 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

INTRODUCTION
Lubrication and maintenance is divided into re-
quired and recommended service tasks. The required
service tasks must be completed to verify emission
controls function correctly. The recommended service
tasks should be completed to maintain safety and du-
rability.
This information will assist service personnel in
providing maximum protection for each owner’s vehi-
cle.
Conditions can vary with individual driving habits.
It is necessary to schedule maintenance as a time in-
terval as well as a distance interval.
It is the owner’s responsibility to determine appli-
cable driving condition. Also to have vehicle serviced
according to the maintenance schedule, and to pay Fig. 1 Vehicle Safety Certification Label
for necessary parts and labor.
SEVERE DRIVING CONDITIONS
Vehicles with a Gross Vehicle Weight Rating
Vehicles subjected to severe driving conditions
(GVWR) of 3 855 kg (8,500 lbs.) or less must conform
should decrease the interval between component
to light duty emission standards. Vehicles with a
maintenance. Severe driving conditions are defined
Gross Vehicle Weight Rating (GVWR) of 3 856 kg
as:
(8,501 lbs.) or more must conform to heavy duty
• Frequent short trip driving less than 24 km (15
emission standards.
miles)
The GVWR for each vehicle is listed on the Safety
• Frequent driving in dusty conditions
Certification Label. This label is affixed to driver side
• Trailer towing
door pillar (Fig. 1).
• Extensive engine idling
Additional maintenance and lubrication informa-
• Sustained high speed operation
tion is listed in the Owner’s Manual.
• Desert operation
• Frequent starting and stopping
• Cold climate operation
• Commercial service
0 - 2 LUBRICATION AND MAINTENANCE Z

When a vehicle is continuously subjected to severe door. Vehicles also have fuel filler tubes that are
driving conditions, lubricate: specially designed to accept only small-diameter
• Body components nozzles.
• All drive line coupling joints
• Steering linkage
More often than normal driving conditions CLASSIFICATION OF LUBRICANTS
Lubricating fluids and chassis lubricants are clas-
DUSTY AREAS sified according to standards recommended by:
With this type of severe driving condition, special • Society of Automotive Engineers (SAE)
care should be given to: • American Petroleum Institute (API)
• Engine air cleaner filter • National Lubricating Grease Institute (NLGI)
• PCV filter
ENGINE OIL (FIG. 2)
• Crankcase ventilation system
• Brake booster control valve air filter. SAE VISCOSITY GRADE
An SAE viscosity grade is used to specify viscosity
OFF-ROAD (4WD) OPERATION
of engine oil. SAE 30 specifies a single viscosity en-
After off-road (4WD) operation, inspect underside
gine oil.
of vehicle. Inspect:
Engine oils also have multiple viscosities. These
• Tires
are specified with a dual SAE viscosity grade which
• Body structure
indicates cold-to-hot temperature viscosity range.
• Steering components
• Suspension components API SERVICE GRADE
• Exhaust system The API Service Grade specifies the type of perfor-
• Threaded fasteners mance engine oil is intended to provide. API Service
Grade specifications also apply to energy conserving
HARSH SURFACE ENVIRONMENTS
engine oils.
After long operation in harsh environments, brake
Conforms to API Service Grade specifications is de-
drums, brake linings, and rear wheel bearings should
termined by tests that measure ability of an oil to
be inspected and cleaned.
control:
• Engine wear
ROUTINE MAINTENANCE
The following routine maintenance is recommended • Bearing corrosion
on a monthly basis: • Sludge
TIRES—Inspect tires for unusual wear/damage. • Varnish
BATTERY—Inspect and clean terminals. Deter- • Oil thickening
mine acid level and add distilled water, if necessary. • Rust
FLUIDS—Determine if component fluid levels are • Piston deposits
acceptable. Add fluid, if necessary. For maximum gasoline engine protection, use API
LIGHTS/ELECTRICAL—Test all electrical systems Service Grade SG, SG/CD or SG/CE engine oil.
in vehicle for proper operation.
It is also recommended that engine oil and washer
fluid level be determined at each fuel fill-up.

FUEL REQUIREMENTS
GASOLINE ENGINES
All engines require use of unleaded gasoline to re-
duce harmful effects of lead to the environment. Also
unleaded fuel is necessary to prevent damage to the
catalytic converter/O2 sensor. Fuel must have a min-
imum octane rating of 87.

CAUTION: UNLEADED FUEL ONLY must be used in

vehicles equipped with a catalyst emission control
system. All vehicles have reminders printed on the
instrument panel below fuel gauge and on fuel filler Fig. 2 SAE Oil Viscosity Grade & API Service Grade
Z LUBRICATION AND MAINTENANCE 0 - 3

GEAR LUBRICANTS GENERAL MAINTENANCE 4.0L ENGINES

A dual grade is also used to specify viscosity of
multi-purpose gear lubricants.
API grade designation identifies gear lubricants in
terms of recommended usage.
MopartSynthetic Gear lube is required for use in
vehicles with a trailer towing package.

CHASSIS COMPONENT AND WHEEL BEARING

LUBRICANTS
Chassis and wheel bearing lubricants that are rec-
ommended are identified by the NLGI Certification
Symbol. The symbol contains a coded designation.
This identifies usage and quality of the lubricant.
The letter G within the symbol designates wheel
bearing lubricant. The letter L designates chassis lu-
bricant. When the letters are combined, the lubricant
can be used for dual applications.

• Drive belt idler pulleys

• Idler arms
• Rubber bushings
• Starter motor bearings
• Suspension strut bearings
• Rear wheel bearings
• Throttle control cables
• Throttle linkage ball joints
• Water pump bearings

Fig. 3 NLGI Lubricant Container Certification/ GENERAL MAINTENANCE 5.2L ENGINES

Identification Symbol
LUBRICATION AND REPLACEMENT PARTS
RECOMMENDATION
Jeeptvehicles are engineered to provide many
years of dependable operation. However, lubrication
service and maintenance are required for each vehi-
cle. When necessary, MOPARtbrand lubricants and
genuine replacement parts are highly recommended.
Each MOPARtbrand lubricant and replacement part
is designed and to provide dependability and long
service life.

COMPONENTS REQUIRING NO LUBRICATION

There are many components that should not be lu-
bricated. The components that should not be lubri-
cated are:
• Generator bearings
• Brake booster cylinder
• Distributors
• Drive belts
0 - 4 LUBRICATION AND MAINTENANCE Z
FLUID CAPACITIES
Z LUBRICATION AND MAINTENANCE 0 - 5

MAINTENANCE SCHEDULES
PARTS AND LUBRICANT RECOMMENDATIONS • Check all lights and all other electrical items for
When service is required, Chrysler Corporation rec- correct operation.
ommends that only Mopart brand parts, lubricants • Check rubber seals on each side of the radiator for
and chemicals be used. Mopart provides the best en- proper fit.
gineered products for servicing Chrysler Corporation
vehicles. 7,500 MILES (12 000 KM) OR AT 6 MONTHS
• Check engine coolant level, hoses and clamps.
INTRODUCTION • Change engine oil.
The maintenance schedule is divided into emission • Replace engine oil filter.
related maintenance and non-emission related main- • Check exhaust system.
tenance. Emission related maintenance is defined as • Lubricate steering linkage.
those maintenance operations which must be per- • Lubricate propeller shaft universal joints.
formed at the mileage specified to assure the contin- • Check automatic transmission fluid level.
ued proper functioning of the emission control • Inspect brake hoses.
system. These, and all other maintenance services in- • Tire Rotation.
cluded in this manual, should be performed to pro-
15,000 MILES (24 000 KM) OR AT 12 MONTHS
vide the best vehicle performance and reliability.
• Check engine coolant level, hoses and clamps.
If a vehicle is subjected to the conditions
• Change engine oil.
listed below (severe service), maintenance
• Replace engine oil filter.
should be performed twice as frequently, for ex-
• Check exhaust system.
ample, every 3 months instead of every 6
• Lubricate steering linkage.
months, or every 3,000 miles (4 800 km) instead
• Lubricate propeller shaft universal joints.
of every 7,500 miles (12 000 km).
• Check automatic transmission fluid level.
• Frequent short trip driving less than 15 miles (24
• Inspect brake hoses.
km).
• Check fluid level in battery.
• Frequent driving in dusty conditions.
• Tire Rotation.
• Trailer towing.
• Frequent long periods of engine idling. 22,500 MILES (36 000 KM) OR AT 18 MONTHS
• Sustained high speed operation. • Check engine coolant level, hoses and clamps.
• Desert operation. • Change engine oil.
• Frequent starting and stopping. • Replace engine oil filter.
• Cold climate operation. • Check exhaust system.
• Off road driving. • Lubricate steering linkage.
• Commercial service. • Lubricate propeller shaft universal joints.
• Check automatic transmission fluid level.
MAINTENANCE SCHEDULES • Inspect brake hoses.
The service intervals are based on odometer read-
• Tire Rotation.
ings in thousands of miles or kilometers. For mileage
beyond that listed, continue maintenance services ev- 30,000 MILES (48 000 KM) OR AT 24 MONTHS
ery 7,500 miles (12 000 km) or more frequently for • Replace air cleaner filter.
severe conditions.
• Replace spark plugs.
AT EACH STOP FOR FUEL • Adjust drive belts (4.0L Only).
• Check engine oil level, add as required. • Check engine coolant level, hoses and clamps.
• Check windshield washer solvent and add if re- • Change engine oil.
quired. • Replace engine oil filter.
• Check exhaust system.
ONCE A MONTH • Lubricate steering linkage.
• Check tire pressure and look for unusual wear or • Lubricate propeller shaft universal joints.
damage. • Inspect brake hoses.
• Inspect battery and clean and tighten terminals as • Check fluid level in battery.
required. • Drain and refill automatic transmission.
• Check electrolyte level and add water as needed. • Drain and refill transfer case.
• Check fluid levels of coolant reservoir, power steer- • Tire Rotation.
ing and transmission and add as needed.
0 - 6 LUBRICATION AND MAINTENANCE Z

37,500 MILES (60 000 KM) OR AT 30 MONTHS Note 1—Recommended by Chrysler but not
• Check engine coolant level, hoses and clamps. required to maintain Warranty on PCV valve.
• Change engine oil.
• Replace engine oil filter. 67,500 MILES (108 500 KM) OR AT 54
• Check exhaust system. MONTHS
• Lubricate steering linkage. • Check engine coolant level, hoses and clamps.
• Lubricate propeller shaft universal joints. • Change engine oil.
• Check automatic transmission fluid level. • Replace engine oil filter.
• Drain and refill manual transmission. • Check exhaust system.
• Inspect brake hoses. • Lubricate steering linkage.
• Tire Rotation. • Lubricate propeller shaft universal joints.
• Check automatic transmission fluid level.
45,000 MILES (72 500 KM) OR AT 36 MONTHS • Inspect brake hoses.
• Check engine coolant level, hoses and clamps. • Tire Rotation.
• Change engine oil.
• Replace engine oil filter. 75,000 MILES (120 500 KM) OR AT 60
• Check exhaust system. MONTHS
• Lubricate steering linkage. • Check engine coolant level, hoses and clamps.
• Lubricate propeller shaft universal joints. • Change engine oil.
• Check automatic transmission fluid level. • Replace engine oil filter.
• Inspect brake hoses. • Check exhaust system.
• Check fluid level in battery. • Lubricate steering linkage.
• Tire Rotation. • Lubricate propeller shaft universal joints.
• Check automatic transmission fluid level.
52,500 MILES (84 500 KM) OR AT 42 MONTHS • Inspect brake hoses.
• Flush and replace engine coolant. • Check fluid level in battery.
• Check engine coolant system hoses and clamps. • Tire Rotation.
• Change engine oil.
• Replace engine oil filter. 82,500 MILES (133 000 KM) OR AT 66
• Check exhaust system. MONTHS
• Lubricate steering linkage. • Flush and replace engine coolant.
• Lubricate propeller shaft universal joints. • Check engine coolant system hoses and clamps.
• Check automatic transmission fluid level. • Change engine oil.
• Inspect brake hoses. • Replace engine oil filter.
• Tire Rotation. • Check exhaust system.
• Lubricate steering linkage.
60,000 MILES (96 500 KM) OR AT 48 MONTHS • Lubricate propeller shaft universal joints.
• Check PCV Valve and replace if necessary 5.2L • Check automatic transmission fluid level.
Only (Note 1). • Inspect brake hoses.
• Replace air cleaner filter. • Tire Rotation.
• Replace distributor cap and rotor (4.0L Only).
• Replace ignition wires. 90,000 MILES (145 000 KM) OR AT 72
• Replace spark plugs. MONTHS
• Replace drive belts (4.0L Only). • Replace air cleaner filter.
• Check engine coolant level, hoses and clamps. • Replace spark plugs.
• Change engine oil. • Adjust drive belts (4.0L Only).
• Replace engine oil filter. • Check engine coolant level, hoses and clamps.
• Check exhaust system. • Change engine oil.
• Replace fuel filter (4.0L Only). (Not required for • Replace engine oil filter.
Calif. vehicles) • Check exhaust system.
• Lubricate steering linkage. • Lubricate steering linkage.
• Lubricate propeller shaft universal joints. • Lubricate propeller shaft universal joints.
• Inspect brake hoses. • Inspect brake hoses.
• Check fluid level in battery. • Check fluid level in battery.
• Drain and refill automatic transmission. • Drain and refill automatic transmission.
• Drain and refill transfer case. • Drain and refill transfer case.
• Tire Rotation. • Tire Rotation.
Z LUBRICATION AND MAINTENANCE 0 - 7

97,500 MILES (157 000 KM) OR AT 78 • Check exhaust system.

MONTHS • Lubricate steering linkage.
• Check engine coolant level, hoses and clamps. • Lubricate propeller shaft universal joints.
• Change engine oil. • Check automatic transmission fluid level.
• Replace engine oil filter. • Inspect brake hoses.
• Check exhaust system. • Tire Rotation.
• Lubricate steering linkage.
• Lubricate propeller shaft universal joints. 120,000 MILES (193 000 KM) OR AT 96
• Check automatic transmission fluid level. MONTHS
• Inspect brake hoses. • Replace air cleaner filter.
• Tire Rotation. • Replace distributor cap and rotor (4.0L Only). (Not
required for Calif. vehicles)
105,000 MILES (169 000 KM) OR AT 84
• Lubricate steering linkage.
MONTHS
• Lubricate propeller shaft universal joints.
• Check engine coolant level, hoses and clamps.
• Inspect brake hoses.
• Change engine oil.
• Replace engine oil filter. • Check fluid level in battery.
• Check exhaust system. • Drain and refill automatic transmission.
• Lubricate steering linkage. • Drain and refill transfer case.
• Lubricate propeller shaft universal joints. • Replace ignition wires.
• Check automatic transmission fluid level. • Replace spark plugs.
• Inspect brake hoses. • Replace drive belts (4.0L Only).
• Check fluid level in battery. • Check engine coolant level, hoses and clamps.
• Tire Rotation. • Change engine oil.
• Replace engine oil filter.
112,500 MILES (181 000 KM) OR AT 90 • Check exhaust system.
MONTHS • Replace fuel filter (4.0L Only).
• Flush and replace engine coolant. • Tire Rotation.
• Check engine coolant system hoses and clamps. Inspection and service should also be performed
• Change engine oil. anytime a malfunction is observed or suspected.
• Replace engine oil filter.
0 - 8 LUBRICATION AND MAINTENANCE Z

JUMP STARTING, HOISTING AND TOWING

JUMP STARTING Verify engine ground (negative) contact sur-
face area is free of grease. Make sure there is a
WARNING: DO NOT ATTEMPT TO PUSH OR TOW A good connection to bare metal. The engine
VEHICLE TO START THE ENGINE. UNBURNED ground (negative) connection must provide
FUEL COULD ENTER THE EXHAUST CATALYTIC good electrical continuity.
CONVERTER AND IGNITE AFTER THE ENGINE IS (5) Start engine.
STARTED. THIS COULD CAUSE THE CONVERTER
TO OVERHEAT AND RUPTURE. WARNING: THE USE OF ANY JUMPER CABLE DIS-
CONNECTION PROCEDURE OTHER THAN THAT
DESCRIBED BELOW COULD RESULT IN:
BOOSTER BATTERY PERSONAL INJURY CAUSED BY BATTERY ACID
SQUIRTING FROM BATTERY VENTS
WARNING: TO PREVENT PERSONAL INJURY, DO PERSONAL INJURY AND/OR PROPERTY DAM-
NOT ALLOW BATTERY ACID TO CONTACT EYES, AGE CAUSED BY BATTERY EXPLOSION
SKIN OR CLOTHING. DO NOT LEAN OVER A BAT- DAMAGE TO THE BOOSTER VEHICLE OR DIS-
TERY WHEN CONNECTING JUMPER CABLES. DO ABLED VEHICLE CHARGING SYSTEM.
NOT ALLOW THE POSITIVE AND NEGATIVE CABLE
CLAMPS TO CONTACT EACH OTHER. KEEP OPEN (7) After engine is started, jumper cables must be
FLAMES AND SPARKS AWAY FROM THE BATTERY disconnected in following order:
• Black (negative) cable connector clamp from en-
ACID VENT HOLES. ALWAYS WEAR EYE PROTEC-
gine ground contact
TION WHEN INVOLVED WITH VEHICLE BATTERIES.
If it becomes necessary to use a booster battery and
jumper cables to start an engine, use the following
procedure.
(1) Engage parking brake. Shift automatic trans-
mission to PARK (if a manual transmission, shift to
NEUTRAL).
(2) Turn off all lights, and all other electrical loads.

WARNING: ACID IN A DISCHARGED BATTERY CAN

FREEZE. DO NOT ATTEMPT TO JUMP START AN
ENGINE BEFORE CHECKING CONDITION OF BAT-
TERY ACID. BATTERY COULD EXPLODE AND
CAUSE SEVERE PERSONAL INJURY.

CAUTION: Do not permit metal surfaces on vehicles

to contact. This could establish ground (negative) Fig. 4 Positive Jumper Cable Connection
continuity between vehicle bodies. This could
cause on-board computers to be damaged.

(3) Attach a red jumper cable connector clamp to

positive (+) terminal on booster battery. Attach other
red cable connector clamp to positive (+) terminal on
discharged battery (Fig. 4).

CAUTION: Do not allow positive (+) and negative (-)

cable clamps to contact each other.

WARNING: DO NOT CONNECT A JUMPER CABLE

CONNECTOR CLAMP TO NEGATIVE POST OF DIS-
CHARGED BATTERY.

(4) Connect a black jumper cable connector clamp

to negative (-) terminal on booster battery. Connect
other black jumper cable connector clamp to a good Fig. 5 Both Jumper Cables Connected On Disabled
ground source on engine that is to be started (Fig. 5). Vehicle
Z LUBRICATION AND MAINTENANCE 0 - 9

• Black (negative) cable connector clamp from nega- • A front suspension arm
tive terminal (-) on booster battery Use correct frame rail lifting locations only
• Red (positive) cable connector clamps from positive (Fig. 6).
(+) terminals on both batteries
HOIST
PORTABLE STARTING UNIT A vehicle can be lifted with:
There are many types of portable starting units • A single-post, frame-contact hoist
available for starting engines. Follow manufacturer’s • A twin-post, chassis hoist
instructions. • A ramp-type, drive-on hoist
When a frame-contact type hoist is used, ver-
HOISTING RECOMMENDATIONS ify that lifting pads are positioned properly
Refer to Owner’s Manual for emergency vehicle lift- (Fig. 6).
ing procedures.
WARNING: WHEN A SERVICE PROCEDURE RE-
FLOOR JACK QUIRES THE REMOVAL OF REAR AXLE, FUEL
When properly positioned, a floor jack can be used TANK, OR SPARE TIRE, EITHER:
to lift a vehicle (Fig. 6). Support vehicle in raised po-
sition with jack stands at front and rear ends of • PLACE ADDITIONAL WEIGHT ON REAR END
frame rails. OF VEHICLE
• ATTACH VEHICLE TO HOIST
• PLACE JACK STANDS UNDER VEHICLE FOR
SUPPORT TO PREVENT TIPPING WHEN CEN-
TER OF BALANCE CHANGES

4WD VEHICLES
A standard hoist can be used to lift a 4WD vehicle.
Hoist should be inspected for adequate clearance.
The lift arms, pads or ramps should be adjusted to
ensure that there is adequate clearance (Fig. 7).

Fig. 6 Correct Vehicle Lifting Locations—Typical Fig. 7 Lifting 4WD Vehicle With Single-Post
Hoist—Typical
CAUTION: Do not attempt to lift a vehicle with a
floor jack positioned under: When a twin-post hoist is used, a 4 x 4 x 12-inch
wood spacer also could be required. Place wood
• An axle tube spacer under front axle. This will maintain balance
• A body side sill and level lifting.
• A steering linkage component
• A drive shaft CAUTION: The block that is used must be secured
• The engine or transmission oil pan in a safe manner. This will ensure that it will not un-
• The fuel tank balance vehicle.
0 - 10 LUBRICATION AND MAINTENANCE Z

TOWING RECOMMENDATIONS • Do not tow vehicle by connecting to front or rear

When it is necessary to tow a vehicle, recom- shock absorbers
mended method is either: • The operator should not go under a vehicle while it
• sling-type, rear-end raised towing method; or is lifted by towing equipment. The vehicle should
• wheel-lift towing method with a tow dolly located first be supported by safety stands
under front wheels. • Do not allow passengers in a vehicle being towed
A vehicle with flat-bed hauling equipment can also • Observe all state and local laws involving warning
be used to transport a disabled vehicle. signals, night illumination, speed, etc.
• Do not exceed a towing speed of 48 km/h (30 mph)
• Avoid towing distances of more than 24 km (15
miles) whenever possible
• Do not attach tow chains or a tow sling to a
bumper, steering linkage, universal joints, or a drive
shaft

REAR-END RAISED TOWING

It is recommended that rear-end raised towing
method be used. Vehicles can be towed with front
wheels on ground for extended distances at speeds
not exceeding 48 km/h (30 mph).
(1) Attach J-hooks around axle shaft tubes out-
board of rear springs.
(2) Position and center sling under and forward of
rear bumper.
Fig. 8 Tow Vehicles With Approved Equipment (3) Attach safety chains (with pads) at each end of
A vehicle equipped with SAE approved sling-type rear bumper.
towing equipment can be used. However, many vehi- (4) Turn ignition switch to OFF position to unlock
cles are equipped with air dams, spoilers, and/or steering wheel.
ground effect panels. In this case a wheel-lift towing (5) Clamp steering wheel with front wheels in
vehicle or a flat-bed hauling vehicle is recommended. straight ahead position.
If a flat bed device is used, approach angle should
CAUTION: Do not use steering column lock to se-
not exceed 15 degrees.
cure front wheels in straight-ahead position.
GROUND CLEARANCE (6) Shift transmission to NEUTRAL.
The lifted wheels of disabled vehicle should be a
minimum of 10 cm (4 in.) off ground. Make sure FRONT-END RAISED TOWING
there is enough clearance at opposite end. This is If a vehicle cannot be towed from rear, front-end
critical when towing over rough terrain. If rear raised towing method normally can be used.
wheels are removed, secure brake drums. A 20 cm (8 (1) Center sling with bumper and position it at
in.) ground clearance must be maintained between frame front crossmember.
brake drums or rotors and ground.
CAUTION: Use tow chains with J-hooks for con-
SAFETY PRECAUTIONS necting to disabled vehicle’s lower suspension
The following safety precautions must be consid- arms. Never use T-hooks.
ered when preparing for and during a vehicle towing
operation: (2) Route J-hooks and tow chains over steering
• Remove exhaust pipe tips that interfere with tow linkage outboard of coil spring.
sling and crossbar (3) Attach J-hooks to outer end of lower suspension
• Padding should be placed between tow sling/cross- arms.
bar and any painted surfaces (4) Raise vehicle.
• If vehicle is damaged, secure loose parts (5) Attach safety chains to disabled vehicle at
• Always use a safety chain system that is indepen- frame rails.
dent of lifting and towing equipment Vehicles equipped with a MANUAL TRANSMIS-
• When placing tow hooks on rear axle, position SION can be towed with rear wheels on ground. Do
them so they do not damage brake tubing or hoses not exceed speeds of 48 km/h (30 mph) or a distance
• Do not allow any of towing equipment to contact of 24 km (15 miles). The transmission must be in
fuel tank neutral.
Z LUBRICATION AND MAINTENANCE 0 - 11

Front-end raised towing for a vehicle equipped with

an AUTOMATIC TRANSMISSION is not recom-
mended.

CAUTION:It is not recommended to flat tow a vehi-

cle.

LOCKED VEHICLE TOWING

When a locked vehicle must be towed, use a tow
dolly or flat bed hauler.

Fig. 9 Front-End Raised Towing—Typical

0 - 12 LUBRICATION AND MAINTENANCE Z

ENGINE MAINTENANCE

INDEX
page page

Air-Conditioner Compressor . . . . . . . . . . . .. . . . . . 17 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 16 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cooling System . . . . . . . . . . . . . . . . . . . .. . . . . . 13 Hoses and Fittings . . . . . . . . . . . . . . . . . . . . . . . . 14
Crankcase Ventilation System . . . . . . . . . .. . . . . . 14 Ignition Cables, Distributor Cap and Rotor . . . . . . . 16
Emr Lamp and Timer Service Information .. . . . . . 14 Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine Air Cleaner Filter Element . . . . . . .. . . . . . 14 Oxygen (O2) Sensor . . . . . . . . . . . . . . . . . . . . . . . 16
Engine Break-In . . . . . . . . . . . . . . . . . . . .. . . . . . 12 Rubber/Plastic Components . . . . . . . . . . . . . . . . . 16
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 12 Serpentine Drive Belt . . . . . . . . . . . . . . . . . . . . . . 16
Engine Oil Change and Filter Replacement . . . . . . 13 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Exhaust Gas Recirculation (EGR) System .. . . . . . 15 Vacuum Operated, Emission Control Components . 15

ENGINE BREAK-IN
After first starting a new engine, allow it to idle for
15 seconds before shifting into a drive gear. Also:
• Drive vehicle at varying speeds less than 88 km/h
(55 mph) for first 480 km (300 miles).
• Avoid fast acceleration and sudden stops.
• Do not drive at full-throttle for extended periods of
time
• Do not drive at constant speeds
• Do not idle engine excessively
A special break-in engine oil is not required. The
Fig. 1 Temperature/Engine Oil Viscosity—Gasoline
original engine oil installed is a high quality, energy
Engines
conserving lubricant.
New engines tend to consume more fuel and oil un- OIL LEVEL INDICATOR (DIPSTICK)
til after the break-in period has ended.
4.0L ENGINES 5.2L ENGINES
ENGINE OIL The engine oil level indicator is located at right
rear of engine on 4.0L engines (Fig. 2).
SPECIFICATIONS The engine oil level indicator is located at the right
front of the engine on 5.2L engines.
API SERVICE GRADE
Use an engine oil that conforms to API Service ACCEPTABLE OIL LEVEL
Grade S, SG/CD or SG/CE. MOPARtprovides engine To maintain proper lubrication of an engine, engine
oils that conform to all of these service grades. oil must be maintained at an acceptable level. The
acceptable level is indicated between ADD and FULL
SAE VISCOSITY
marks on engine oil level dipstick.
An SAE viscosity grade is used to specify viscosity of The oil level should be checked periodically. The ve-
engine oil. SAE 30 specifies a single viscosity engine oil.
hicle should be on a level surface. Wait for five min-
Engine oils also have multiple viscosities. These
utes after stopping engine or after vehicle has
are specified with a dual SAE viscosity grade which
remained parked overnight. For 4.0 engines, add en-
indicates cold-to-hot temperature viscosity range. Se-
gine oil only when level indicated on dipstick is at or
lect an engine oil that is best suited to your particu-
lar temperature range and variation (Fig. 1). below ADD mark.

ENERGY CONSERVING OIL CAUTION: Do not overfill an engine crankcase with

oil.
An Energy Conserving type oil is recommended for
gasoline engines. They are designated as either EN-
ERGY CONSERVING or ENERGY CONSERVING II.
Z LUBRICATION AND MAINTENANCE 0 - 13

ENGINE OIL FILTER

All engines are equipped with a high quality full-
flow, throw-away type oil filter. The same type of fil-
ter is recommended when filter is changed.

OIL CHANGE AND FILTER REPLACEMENT

Bring engine up to normal operating temperature.
A more complete drainage of oil will result.
(1) Remove drain hole plug. Drain engine oil from
crankcase.
(2) Install drain hole plug with a replacement gas-
ket.
For gasoline engines, oil filter should be replaced
during every second engine oil change.
(3) Rotate oil filter counterclockwise to remove it.
(4) Clean engine cylinder block oil filter boss.
(5) Apply a light coat of new engine oil to rubber
seal on oil filter.
(6) Install and hand tighten oil filter 1/2 to 3/4 of a
turn clockwise beyond point where seal first contacts
cylinder block boss.
Fig. 2 Engine Oil Dipstick Location 5.2L Engine— (7) Add specified quantity of new engine oil at fill
Typical hole location on top of engine cylinder head cover.
Wipe off any spilled oil.
(8) Observe oil level on dipstick. Adjust as neces-
sary.
(9) Start engine. Observe oil pressure gauge or
warning lamp (as applicable). If oil pressure does not
increase, stop engine immediately and determine
cause of malfunction.

Fig. 3 Engine Oil Dipstick—4.0L Engine

ENGINE OIL CHANGE AND FILTER REPLACEMENT
WARNING: CARE SHOULD BE EXERCISED WHEN
CHANGING ENGINE OIL TO MINIMIZE THE LENGTH
OF EXPOSURE TIME TO USED ENGINE OIL. PRO-
TECTIVE CLOTHING AND GLOVES SHOULD BE Fig. 4 Oil Filter—4.0L Engine
WORN. EXPOSED SKIN SHOULD BE THOROUGHLY
WASHED WITH SOAP AND WATER TO REMOVE COOLING SYSTEM
ANY USED ENGINE OIL. DO NOT USE GASOLINE, WARNING: USE EXTREME CAUTION WHEN THE
THINNER, OR SOLVENTS TO REMOVE USED EN- ENGINE IS OPERATING. DO NOT PUT YOUR
GINE OIL FROM SKIN. DO NOT POLLUTE. DISPOSE HANDS NEAR DRIVE BELT(S), PULLEYS OR FAN
OF USED ENGINE OIL PROPERLY. CONTACT YOUR BLADE. DO NOT STAND IN A DIRECT LINE WITH
DEALER OR GOVERNMENT AGENCY FOR LOCA- FAN BLADE.
TION OF COLLECTION CENTER IN YOUR AREA.
0 - 14 LUBRICATION AND MAINTENANCE Z

INSPECTION SCHEDULE Drain, flush, and fill cooling system with correct
Determine coolant level. Inspect cooling system coolant mixture at interval specified in maintenance
hoses/clamps after each service interval has elapsed. schedule.

COOLANT LEVEL HOSES AND FITTINGS

It is recommended that engine coolant level be in- It is recommended that rubber hoses be periodi-
spected at least once a month during periods of hot cally inspected. Inspect all hose fittings for looseness
weather. and corrosion. Inspect rubber hoses for brittleness
With engine at normal operating temperature, and cracks.
check coolant level in coolant reserve tank. Coolant
level must be at least above ADD mark and prefera- ENGINE AIR CLEANER FILTER ELEMENT
bly at FULL mark. Add coolant to coolant reserve
tank only.
MAINTENANCE SCHEDULE
With normal driving conditions, engine air cleaner
COOLANT FREEZE PROTECTION filter element should be replaced:
Cooling systems contain a 50/50 mixture of anti- • Light-Duty Cycle—after each 48 000 km (30,000
freeze and distilled water. This is the recommended miles) interval has elapsed
coolant mixture. The factory installed anti-freeze is • Heavy-Duty Cycle—after each 38 000 km (24,000
formulated to prevent corrosion on all cooling system miles) interval has elapsed
metal surfaces. When vehicle is operated in dusty areas, filter ele-
It is recommended that degree of coolant protection ment should be replaced more often.
be tested every 12 months. If coolant is contaminated
or rusty, cooling system should be drained and
SERVICE/REPLACEMENT
(1) Remove air cleaner cover.
flushed. Refill with a 50/50 mixture of fresh coolant.
(2) Remove air cleaner filter (Fig. 5).
Refer to Group 7—Cooling Systems for additional in-
formation. CAUTION: Do not tap filter or immerse filter me-
dium in liquid to remove trapped debris.
SYSTEM INSPECTION

WARNING: IF THE ENGINE HAS BEEN RECENTLY (3) Clean filter by gently blowing trapped debris
OPERATED, DO NOT REMOVE RADIATOR CAP. from filter medium with compressed air. Direct air in
opposite direction of normal intake air flow. Keep air
(1) Test radiator cap for proper vacuum sealing nozzle at least two inches away from filter element.
and operation. Use caution when removing radiator (4) If filter medium has become partially saturated
cap to avoid contact with hot coolant. Place a heavy with oil, replace filter element. Inspect crankcase
rag or towel over cap and turn to first stop. Do not ventilating system for proper operation.
press down. Pause to allow pressure to release (5) Wash air cleaner cover and body with cleaning
through overflow tube. Then press down and turn solvent. Wipe it dry.
counterclockwise to remove cap. (6) Install air cleaner filter element. Attach cover
(2) Inspect coolant overflow tubing and connections to body (Fig. 5).
at coolant reserve tank and at radiator.
(3) Inspect entire cooling system for leaks. A black- EMR LAMP AND TIMER SERVICE INFORMATION
Refer to Group 25—Emission Control Systems for
light detector can be used as an aid in detecting
timer reset and other related information.
source of coolant leaks.
(4) Inspect radiator and air conditioner condenser
CRANKCASE VENTILATION SYSTEM
fins for an accumulation of debris. All Jeept engines are equipped with a crankcase
(5) If necessary, refer to Group 7—Cooling Systems ventilation (CCV) system. The vapor is routed back
for additional information and service procedures. to be burned in engine combustion chambers (Fig. 6).
RADIATOR CAP SYSTEM OPERATION
The radiator cap must be completely tightened to The 4.0L engine closed crankcase ventilation (CCV)
provide proper pressure release and coolant recovery. system has a vapor-transfer fitting located on the cyl-
inder head cover. A molded hose is connected between
DRAIN, FLUSH AND FILL
the intake manifold and the fitting.
WARNING: ANTI-FREEZE IS POISONOUS. KEEP
OUT OF REACH OF CHILDREN.
Z LUBRICATION AND MAINTENANCE 0 - 15

GAS0LINE ENGINE FUEL REQUIREMENTS

All gasoline engines require fuel that has a mini-
mum octane rating of 87 determined by (R + M)/2
calculation method.
In addition, use of a brand of unleaded gasoline
that contains detergent, corrosion and stability addi-
tives is recommended. Gasoline with these type of
additives will improve fuel economy and reduce emis-
sions.

ALCOHOL/GASOLINE BLENDS
Many brands of blended unleaded gasoline are now
available. This type of blended fuel is sometimes re-
ferred to as reformulated gasoline.
Unleaded gasoline is blended with oxygenated-type
fuels to produce a clean air gasoline in many areas.
The use of this type of blended fuel is recommended.
ETHANOL—Unleaded gasoline and ethanol
blended fuels are a mixture of 10 percent ethanol
and 90 percent unleaded gasoline. This is an accept-
able blend of fuel.
MTBE— MTBE blended fuels are a mixture of un-
Fig. 5 Engine Air Cleaner
leaded gasoline and up to 15 percent MTBE (Methyl
RECOMMENDED MAINTENANCE Tertiary Butyl Ether). Unleaded gasoline blended
Crankcase ventilation (CCV) systems should be with MTBE is acceptable.
tested, inspected and serviced at the same time as ETBE— This fuel is a mixture of unleaded gasoline
the air filter. and up to 17 percent ETBE (Ethyl Tertiary Butyl
Refer to Group 25—Emission Control Systems for Ether). Unleaded gasoline blended with ETBE is ac-
additional serviced information. ceptable.
METHANOL—Do not use unleaded gasoline
blended with methanol. The use of this type of alco-
hol can result in engine performance deterioration
and damage to critical components.
Engine problems that result from use of meth-
anol possibly will not be covered by new vehi-
cle warranty.

ADDITIVES MIXED WITH GASOLINE

Use of fuel system cleaning additives should be
avoided. Many of these solutions could contain highly
active solvents.

VACUUM OPERATED, EMISSION CONTROL

COMPONENTS
The vacuum operated emission control components
Fig. 6 CCV System—4.0L Engine should be serviced at interval specified in mainte-
nance schedule.
FUEL SYSTEM
Refer to Group 25—Emission Control Systems for
INSPECTION additional information.
The fuel system filler cap, nozzle, tubes, hoses, and
connections should be inspected periodically. EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Replace EGR valve and tube, and clean passages at
FUEL FILTER interval specified in applicable maintenance sched-
Replace fuel filter at interval specified in mainte- ule. If necessary, refer to Group 25—Emission Con-
nance schedule. For proper diagnosis and service pro- trol Systems for additional information.
cedures refer to Group 14, Fuel System.
0 - 16 LUBRICATION AND MAINTENANCE Z

OXYGEN (O2) SENSOR (2) Clean the battery cable clamps and terminal
Replace O2 sensor at interval specified in applica- posts with a wire brush and a battery terminal
ble maintenance schedule. cleaner.
(3) Pry the battery cell filler caps upward to re-
IGNITION CABLES, DISTRIBUTOR CAP AND move them and inspect each filler well. It could pos-
ROTOR sibly be necessary to loosen the battery hold down
Replace ignition cables, distributor cap, and rotor clamp to remove the caps. Maintain the acid level
at interval specified in applicable maintenance sched- above the battery plates and at the bottom of the
ule. Refer to Group 8D—Ignition Systems for addi- filler well ring. Add distilled water or low - mineral
tional information. content drinking water, if necessary. In freezing
weather (below 0°C/32°F), add the water just before
IGNITION TIMING driving to ensure that it mixes. This will prevent it
Test and adjust, if necessary, ignition timing at in- from freezing.
terval specified in applicable maintenance schedule. (4) Remove the battery hold down strap and clean
Refer to specifications listed on engine Emission Con- the battery case/battery tray. Clean with a bicarbon-
trol Information label. Refer to Group 8D—Ignition ate of soda and water. Rinse and dry the battery
Systems and to Group 25—Emission Control Systems case/tray thoroughly after cleaning.
for additional service information. (5) Position the battery in the tray and install the
hold down strap. Do not over-tighten the nuts.
SPARK PLUGS (6) Connect the battery positive cable and then the
Replace spark plugs at interval specified in appli-
negative cable to the battery.
cable maintenance schedule. Refer to Group 8D—Ig-
(7) Apply a small amount of chassis lubricant ( or
nition Systems for additional information.
an equivalent protective coating) to the cable termi-
BATTERY nals to minimize corrosion.
Replace battery at interval specified in applicable
maintenance schedule. RUBBER/PLASTIC COMPONENTS

RECOMMENDED MAINTENANCE INSPECTION

The battery acid level should be checked and the It is recommended that following listed components
cable clamps should be inspected for corrosion. This be inspected at same time as scheduled underhood
should be done when the engine oil is changed and maintenance is conducted. Rubber/plastic compo-
the oil filter is replaced. nents should be replaced immediately if there is any
The battery cables should be inspected for abnor- evidence of deterioration.
mal clamp and battery terminal post corrosion. Ser- Inspect exterior surface of rubber hoses and nylon
vice the terminals and cable clamps as necessary. tubing for evidence of heat damage. The rubber hose
and nylon tubing located close to an exhaust mani-
INSPECTION/SERVICE fold should be given attention. Verify nylon tubing lo-
cated at these areas has not collapsed.
WARNING: WEAR SAFETY GLASSES, RUBBER Inspect rubber hose routing to ensure that hoses do
GLOVES AND PROTECTIVE CLOTHING WHEN HAN- not contact any heat source or moving component.
DLING/SERVICING A BATTERY. THE BATTERY CON- Inspect all hose connections. Verify they are secure
TAINS SULFURIC ACID AND WILL CAUSE HARM IF and there is no fluid leakage.
IT CONTACTS SKIN, EYES OR CLOTHING. IT WILL
ALSO DAMAGE PAINTED (AS WELL AS UN- ENGINE MOUNTS
PAINTED) SURFACES OF A VEHICLE. IF SULFURIC Inspect rubber in the engine mounts for excessive
ACID CONTACTS ANY OF THESE, FLUSH IMMEDI- wear. Slight wear at ends will not affect functioning
ATELY WITH LARGE AMOUNTS OF WATER. IF SUL- of an engine mount. If excessive engine movement is
FURIC ACID CONTACTS SKIN OR EYES, GET detected, engine mount(s) should be replaced.
IMMEDIATE MEDICAL ATTENTION. DO NOT SMOKE
IN THE VICINITY OF A BATTERY. KEEP OPEN SERPENTINE DRIVE BELT
Replace drive belt and adjust drive tension at in-
FLAMES AND SPARKS AWAY FROM BATTERY
terval specified in applicable maintenance schedule.
FILLER CAPS BECAUSE EXPLOSIVE GAS IS AL-
If necessary, refer to Group 7—Cooling Systems for
WAYS PRESENT.
replacement and adjustment and procedures.
(1) Disconnect the battery negative cable and then
the positive cable.
Z LUBRICATION AND MAINTENANCE 0 - 17

INSPECTION CAUTION: A catalytic converter will become con-

It is recommended that serpentine drive belt be taminated if leaded gasoline is burned in engine. If
routinely inspected for cracks, fraying and excessive this occurs, complete converter must be replaced.
wear.

EXHAUST SYSTEM AIR-CONDITIONER COMPRESSOR

An exhaust system must be properly aligned to
prevent stress, leakage, and vehicle body contact. LUBRICANT AND REFRIGERANT
Inspect exhaust system at interval specified in ap- The lubricant level in air-conditioner compressor
plicable maintenance schedule. should be checked if there are indications that oil
was lost. Loss of lubricating oil usually accompanies
INSPECTION a loss of refrigerant. The presence of bubbles in filter/
Inspect for cracked or loose joints, corrosion dam- drier sight glass indicates that loss of refrigerant has
age, and worn or broken hangers. Replace all compo- occurred.
nents that are damaged. Do not attempt repair.: For additional information involving A/C system,
• Exhaust system leaks, misalignment refer to Group 24—Heater And Air Conditioning.
• Contact with body panels or frame
• Catalytic converter bulging or excessive heat dam-
age
0 - 18 LUBRICATION AND MAINTENANCE Z

DRIVETRAIN

INDEX
page page

Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Clutch and Brake Pedal Bushings . . . . . . . . . . . . . 18 Transfer Case (4WD Vehicles) . . . . . . . . . . . . . . . . 19
Clutch Master Cylinder . . . . . . . . . . . . . . . . . . . . . 18 Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

CLUTCH AND BRAKE PEDAL BUSHINGS

If clutch and brake pedal mechanism squeaks,
pivot bushings should be lubricated. Use
MOPARtMulti-Purpose Lubricant, or an equivalent.

CLUTCH MASTER CYLINDER

HYDRAULIC FLUID LEVEL
The clutch master cylinder fluid level should be in-
spected at same time as scheduled underhood main-
tenance is conducted. The fluid level should be at
internal indicating line (Fig. 1). If fluid level is low,
locate and correct any possible leaks. Fill reservoir
with clean, moisture-free brake fluid.

CAUTION: Do not allow any petroleum base fluids

to contaminate clutch hydraulic system because Fig. 1 Fluid Level Indicating Ring
seal damage will result. • AX15 manual transmission—every 29 000 km
(18,000 miles)
FLUID SPECIFICATION • Automatic transmission—every 19 000 km (12,000
The only fluid recommended for use is miles)
MOPARtBrake Fluid, or an equivalent product. The A severe driving condition includes:
product is identified as SAE J-1703 or DOT 3 flu- • Extended operation with heavy cargo loads
id.Do not use any other type of fluid. • Driving in deep mud or snow
• Off-road operation (4WD)
CAUTION: Never use reclaimed brake fluid or fluid • Trailer towing
from an unsealed container. Do not use fluid that • Operation as a commercial vehicle
has been opened and allowed to stand for an ex- • Snow plowing
tended length of time.
MANUAL TRANSMISSIONS
TRANSMISSIONS INSPECTION/LUBE OIL LEVEL
The manual transmission should be inspected for
SPECIAL ADDITIVES
Chrysler Motors does not recommend addition of leakage whenever other service is necessary under
any special additives to a transmission. Black light vehicle. To check lube oil level, remove fill hole plug
detection dye can be used as an aid in detecting fluid (Fig. 2 ). If level is below bottom of fill hole, raise
leaks. level to bottom of fill hole with:
• SAE 75W90, API Quality Grade GL-5 gear lubri-
GEAR SHIFTER BOOTS cant
Inspect shifter boots periodically for stone and heat
damage. Replace, if necessary. DRAIN AND FILL
The AX15 transmission fluid should be changed ac-
SEVERE DRIVING CONDITIONS cording to interval listed in Maintenance Schedule.
The interval between transmission drain and refill Also, refer to Fluid Capacities chart.
maintenance should be decreased to:
Z LUBRICATION AND MAINTENANCE 0 - 19

DRAIN, FILTER CHANGE, BAND ADJUSTMENT AND REFILL

The Maintenance Schedule chart lists intervals at
which transmission should be serviced. Also, refer to
Fluid Capacities chart for fill capacity.
The torque converter does not have a drain plug.
No attempt should be made to drain converter. Refer
to Group 21—Transmissions for transmission drain
and refill procedures.

TRANSFER CASE (4WD VEHICLES)

INSPECTION
The transfer case fluid level should be checked
whenever maintenance is necessary under vehicle.

FLUID LEVEL
Fig. 2 Manual Transmission Fill/Drain Hole Plugs The vehicle must be level when fluid level is
checked.
AUTOMATIC TRANSMISSIONS
The transfer case drain/fill hole plugs are located
at rear of housing (Fig. 3).
FLUID LEVEL
Determine transfer case fluid level according to fol-
It is recommended that fluid (ATF) level in auto- lowing procedure.
matic transmissions be checked while involved with (1) Raise and support vehicle.
other underhood maintenance. (2) Remove fill hole plug (Fig. 3). The fluid level
Vehicle operation with an incorrect ATF level should be at bottom edge of fill hole. The level can be
will greatly reduce life of transmission. slightly below bottom edge of fill hole if fluid is cold.
The condition of ATF also should be determined. If (3) If level is not acceptable, raise fluid level to
ATF is dark in color and has a strong odor, fluid bottom edge of fill hole with:
should be changed. Also filter should be replaced and • MOPARtATF PLUS or an equivalent Dexron IIt
bands adjusted. ATF.
The following procedure must be used to check au- Add fluid in small amounts to raise level.
tomatic transmission fluid (ATF) level. (4) Install fill hole plug (Fig. 3). Tighten fill hole
(1) Position vehicle on level ground. plug to 27 Nzm (20 ft-lbs) torque.
(2) Operate engine at idle speed. (5) Remove support and lower vehicle.
(3) Apply parking brake.
(4) Place gear selector in N (neutral).
(5) Remove dipstick from tube. Wipe it clean and
determine if ATF is hot or warm.
Hot ATF has a temperature of approximately
82°C (180°F). Warm ATF is when its temperature
is between 29-52°C (85-125°F).
(6) Wipe dipstick clean and completely insert it
into tube. Remove dipstick from tube and observe
ATF level.
(7) If ATF is hot, level should be in crosshatched
area that is marked OK.
(8) If ATF is warm, level should be between two
dimples.

CAUTION: Do not overfill transmission.

Fig. 3 Transfer Case—Typical
(9) Adjust level of ATF accordingly.
FLUID DRAIN AND REFILL
It is important to use correct fluid in AW4 au-
(1) Raise and support vehicle.
tomatic transmission. Mercon™ ATF should be
(2) Remove fill hole plug (Fig. 3) from transfer
used.
case.
(10) Insert dipstick into tube. (3) Place an appropriate container under transfer
case drain hole plug (Fig. 3).
0 - 20 LUBRICATION AND MAINTENANCE Z

(4) Remove drain hole plug. Drain fluid from cles) differential housings have a threaded-type fill
transfer case into container. plug (Fig. 5). Remove fill plug from differential hous-
ing.
CAUTION: Do not over-tighten drain and fill hole
plugs.

(5) Install drain hole plug (Fig. 3). Tighten drain

hole plug to 27 Nzm (20 ft-lbs) torque.
(6) Fill transfer case to bottom edge of fill hole
with:
• MOPARtATF PLUS or an equivalent Dexron IIt
ATF
(7) Install fill hole plug. Tighten plug to 27 Nzm
(20 ft-lbs) torque.
(8) Remove support and lower vehicle.

FLUID SPECIFICATION
• MOPARtATF PLUS or an equivalent Dexron IIt
ATF

SHIFT MECHANISM
The transfer case shift mechanism should be
cleaned and lubricated as necessary to maintain ease
of operation.
Lubricate pivot, sliding contact areas and shift
linkage pivot ends with light-weight engine oil (Fig.
Fig. 5 Axle Fill Plug Location—Typical
4).
(3) The lubricant level should be within 12 mm
(1/2 in) of fill hole.
(4) If necessary, add lubricant.
(5) Install fill hole plug in differential housing (Fig.
5).

DRAIN AND REFILL

Periodic axle lubricant change for normal vehicle
operation is not necessary. However, lubricant should
be changed if it is contaminated. Refer to chart be-
low.All axles contain SAE 80W-90 multi-purpose
type hypoid gear lubricant when delivered
from factory.
Use same maintenance procedures for rear
axles equipped with a limited-slip differential.

Fig. 4 Shift Mechanism Lubrication—Typical LUBRICANT VISCOSITIES FOR ANTICIPATED

TEMPERATURE RANGES
AXLES
INSPECTION
For normal vehicle operation, periodic axle lubri-
cant level checks are not necessary. However, exterior
of axle housing should be inspected for leakage.
Check lubricant level to confirm leakage.

LUBRICANT LEVEL
(1) Raise vehicle with an axle or wheel type hoist.
Support vehicle.
(2) The rear axle differential housings have a rub-
ber, PRESS-IN type fill plug (Fig. 5). Pry fill plug
from differential housing. The front axle (4WD vehi-
Z LUBRICATION AND MAINTENANCE 0 - 21

CAUTION: Water contaminated gear lubricant will (4) Cover pressure relief hole with a finger. Con-
result in possible failure of axle differential compo- tinue to force lubricant into fitting until it appears at
nents. Operation of vehicle in water, will require slip-yoke seal.
that:
U-JOINT/CV-JOINT LUBRICATION
• The lubricant be drained Lubrication of u-joint couplers that are not
• The differential housing flushed (except limited- equipped with lube (Zerk) fittings is not necessary.
slip differentials) Replacement U-joints are equipped with lube fittings.
• The differential refilled with fresh lubricant If installed, lubricate them according to information
provided below.
LUBRICANT SPECIFICATION
Lubricate U-joint and CV-joints every 12 000 km
A multi-purpose, hypoid gear lubricant should be
used in all axles equipped with either a standard or (7,500 miles) for LIGHT DUTY CYCLE vehicles. For
a limited-slip differential. The use of MOPARt Syn- HEAVY DUTY CYCLE vehicles, couplers should be
thetic Axle Lube is necessary with trailer towing lubricated every 9 600 km (6,000 miles). If vehicle is
package. Trac-Loc axles require a friction additive. operated in water, U-joint/CV-joint couplers should be
lubricated daily.
FRONT AXLE PIVOT BEARINGS (4 W/D) If a vehicle, is used in a severe driving condition,
The front axle universal joint and pivot bearings lubricate U-joint/CV-joints every 4 800 km (3,000
are permanently lubricated and normally do not re- miles).
quire service. A severe driving condition includes:
• Off-road driving
DRIVE SHAFTS • Driving in deep mud or snow
• When 1/3 or more of vehicle operation involves
SLIP-YOKE LUBRICATION
When equipped with lube fittings, it is recom- driving with a full-load.
mended that slip-yoke splines be lubricated every 9
LUBRICANT SPECIFICATION
600 km (6,000 miles). For severe usage, lubricate
Drive shaft slip yokes and U-joint/CV-joint couplers
splines every 1 600 km (1,000 miles).
should be lubricated with, NLGI GC-LB lubricant.
The method described below will ensure complete
lubrication of slip-yoke splines. The U-joints/CV-joint couplers should be lubricated
(1) Clean Zerk type lubrication fittings. with MOPARtMultipurpose Lubricant, NLGI GC-
(2) Use a lubricant dispenser to force lubricant into LB).
slip yoke Zerk type lubrication fittings.
(3) Continue lubricating until it appears at pres-
sure relief hole in expansion plug located at slip-yoke
end.
0 - 22 LUBRICATION AND MAINTENANCE Z

CHASSIS AND BODY

INDEX
page page

Body Component Mechanisms . . . . . . . . . . . . . . . 24 Power Brake System . . . . . . . . . . . . . . . . . . . . . . . 23

Front Suspension Ball Joints . . . . . . . . . . . . . . . . . 22 Power Steering System . . . . . . . . . . . . . . . . . . . . . 22
Front Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . 23 Speedometer Cable . . . . . . . . . . . . . . . . . . . . . . . 25
Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Steering Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Lower and Upper Suspension Arm Bushings . . . . . 23 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

STEERING LINKAGE LUBRICATION SCHEDULE

INSPECTION The front suspension ball joints are semi-perma-
Whenever a vehicle is raised for lubrication/general nently lubricated during manufacture with a special,
maintenance under vehicle, all steering components long-life chassis lubricant. However, it is recom-
should be inspected. mended that ball joints be inspected and studs lubri-
cated:
LUBRICATION SCHEDULE • At each 36 000 km (22,500 miles) interval or every
The steering linkage is lubricated during manufac- 2 years, for vehicles subject to LIGHT DUTY CYCLE
ture with a long-life chassis lubricant. However, it is Maintenance Schedule
recommended that linkage be inspected and lubri- • At each 9 600 km (6,000 miles) interval or every 2
cated after each: years, for vehicles subject to HEAVY DUTY CYCLE
• 24 000 km (15,000 miles) interval or every 6 Maintenance Schedule.
months, for 2WD vehicles subject to LIGHT DUTY 4WD vehicles that are frequently driven off-
CYCLE Maintenance Schedule road should be lubricated at every engine oil
• 9 600 km (6,000 miles) interval or every 6 months, change.
for 2WD vehicles subject to HEAVY DUTY CYCLE
Maintenance Schedule LUBRICATION
• 12 000 km (7,500 miles) interval or every 6 (1) Inspect front suspension.
months, for 4WD vehicles subject to LIGHT DUTY (2) Replace all torn ball-stud seals and damaged
CYCLE Maintenance Schedule ball joints. Damaged seals should be replaced to pre-
• 9 600 km (6,000 miles) interval or every 6 months, vent leakage and contamination.
for 4WD vehicles subject to HEAVY DUTY CYCLE
Maintenance Schedule. CAUTION: Use care to prevent lubricant from con-
tacting brake rotors.
LUBRICATION
(1) Inspect steering linkage for looseness and ex- (3) Lubricate ball studs:
cessive wear. • Clean Zerk type lubrication fittings on ball-stud
(2) Replace, all ruptured seals and damaged steer- ends
ing linkage components. • Lubricate ball studs with MOPARtMulti-Mileage
Lubricant
CAUTION: Use care to prevent lubricant from con- • Wipe excess lubricant from exterior surfaces of ball
tacting brake rotors. joints
(3) Lubricate steering linkage: POWER STEERING SYSTEM
• Clean Zerk type lubrication fittings on tie-rod and
center link ball-stud ends FLUID LEVEL
• Lubricate ball studs with MOPARtMulti-Mileage
Lubricant WARNING: THE POWER STEERING FLUID LEVEL
• Wipe excess lubricant from exterior surfaces of ball SHOULD ALWAYS BE DETERMINED WITH THE EN-
joints GINE OFF TO PREVENT PERSONAL INJURY FROM
ROTATING ENGINE COMPONENTS.
FRONT SUSPENSION BALL JOINTS
The power steering fluid should be checked when-
INSPECTION ever engine is being serviced for other reasons. Clean
When a vehicle is raised for lubrication/general outside of cap before removing. The fluid should be at
maintenance, ball joints should be inspected. proper level indicated on cap dipstick (Fig. 2).
Z LUBRICATION AND MAINTENANCE 0 - 23

LOWER AND UPPER SUSPENSION ARM

BUSHINGS
INSPECTION SCHEDULE
The lower and upper suspension arm bushings
should be inspected each time underside of vehicle is
serviced.

INSPECTION
The lower suspension arm bushings can be visually
inspected by raising vehicle on a hoist and inspecting
from underneath. The upper suspension arm bush-
ings can be inspected after removing front wheels. If
failure exists, replace bushing (refer to Group
2—Front Suspension for proper procedures).
The suspension arm bushings never should be
Fig. 1 Steering Components—Typical lubricated.

GUIDELINES
(1) Faulty bushings are detected by bushing being
off-center in relation to outer sleeve.
(2) Total failure is evident by excessive movement
within bushing.
(3) Small cracks in outer, non-confined rubber does
not indicate failure of rubber.

POWER BRAKE SYSTEM

Vehicles are equipped with power disc brakes at
front wheels and drum brakes at rear wheels.

FLUID SPECIFICATION
Power brake systems require MOPARtHeavy-Duty
Brake Fluid.
The use of an equivalent product identified with
FMVSS No. 116, DOT-3 and SAE J-1703 Standard
designations is permissible.
Use fresh brake fluid only when adding fluid to
Fig. 2 Power Steering Reservoir & Cap—Typical reservoir. Never use fluid that does not conform to
The reservoir fluid level can be determined with DOT/SAE Standards, or fluid from a container that
fluid either hot or cold. If fluid level is below FULL has been left open.
HOT or FULL COLD marks on dipstick, add power
steering fluid. The dipstick is attached to reservoir CAUTION: The use of a substandard brake fluid
cap (Fig. 2). could result in sudden brake failure during hard,
prolonged braking.
FLUID SPECIFICATION
Use only MOPARtPower Steering Fluid.
CAUTION: Do not allow petroleum base fluids to
contaminate brake fluid. Seal damage will result.
FRONT WHEEL BEARINGS
The front wheel bearings on a ZJ vehicle are per-
manently lubricated. If service is necessary refer to BRAKE FLUID LEVEL
Group 2—Front Suspension And Axle.
ANTI-LOCK BRAKE SYSTEM
The anti-lock brake system fluid reservoir is lo-
cated in engine compartment at left side of dash
panel.
(1) Clean cover before removing it.
0 - 24 LUBRICATION AND MAINTENANCE Z

CAUTION: Over-filling could cause fluid overflow • Pulling

and possible reservoir damage when pump motor • Scuffing
energizes. • Excessively worn areas
(1) Inspect all hoses for kinks, a distorted condi-
(2) The brake fluid level should be no lower than tion and fluid leakage.
MIN arrow indicator on side of reservoir. If not, add (2) Inspect hose and tubing routing under vehicle.
brake fluid as necessary. Raise fluid level to MAX ar- Verify that no hose/tubing is rubbing against any un-
row indicator only. Do not over-fill reservoir. der body components.

PARK BRAKE
(1) Engage park brake lever and then release it.
(2) Test parking brake for smooth operation and
vehicle-holding capability.
(3) Inspect park brake cables for kinks, fraying
and a binding condition.
(4) With park brake released, rear wheels should
rotate without restriction. Adjust park brake cable
tension at equalizer. Refer to Group 5—Brakes, for
component information.
(5) Repair any park brake malfunctions.

BRAKE OPERATIONAL TEST

(1) Drive vehicle and test for proper brake action.
(2) Note any indication of brake overheating, wheel
Fig. 3 Reservoir Fluid Level—Anti-Lock Brake dragging or vehicle pulling to one side.
System (3) Evaluate any performance complaints received
BRAKE SYSTEM INSPECTION from owner/operator.
(1) Inspect brake pads and linings for excessive (4) Repair brake system as necessary (refer to
wear, cracks and broken rivets. Group 5—Brakes for additional information and ser-
(2) Inspect brake pads and linings for contamina- vice procedures).
tion with brake fluid, axle lubricant and/or other flu-
ids. BODY COMPONENT MECHANISMS
(3) Replace front brake pads and rear brake lin- LUBRICATION REQUIREMENTS
ings if they are worn to within 0.78 mm (1/32 in) of a All operating mechanisms and linkages should be
rivet head. lubricated when necessary. This will maintain ease of
(4) Operate rear brake self-adjuster lever and operation and provide protection against rust and ex-
pivot. Test operation of self-adjuster screw for ease of cessive wear. Door weatherstrip seals should be lu-
movement. bricated to prolong their life as well as to improve
(5) Inspect self-adjuster components for frayed ca- door sealing.
bles. Inspect for loose or overheated springs, or a
binding condition. LUBRICANT SPECIFICATIONS
(6) Inspect caliper dust boots for damage or tears. All applicable exterior and interior vehicle operat-
Inspect for an indication of brake fluid leakage. In- ing mechanisms should be:
spect bushings and pins for corrosion. Inspect for • Inspected
tears or a binding condition. • Cleaned
(7) Inspect rear wheel cylinder dust boots for fluid • All pivoting/sliding contact areas on mechanisms
leaks. Inspect pistons and cylinder bores for proper should then be lubricated.
appearance. MOPARtMulti-Mileage Lubricant or an equivalent,
(8) Inspect brake differential warning valve and should be used to lubricate mechanisms. The door
housing for indications of leakage, kinked hoses and weatherstrip seals should be lubricated with silicone
loose fittings. lubricant spray. Refer to Body Lubricant Specifica-
tions chart below for additional lubricant applica-
BRAKE HOSES/TUBING tions.
The rubber brake hoses should be inspected for:
• Correct length LUBRICATION
• Severe surface cracking (1) When necessary, lubricate body component op-
• Swelling erating mechanisms with specified lubricants.
Z LUBRICATION AND MAINTENANCE 0 - 25

BODY LUBRICANT SPECIFICATIONS

(2) Apply silicone lubricant to a cloth. Wipe it on door INSPECTION

seals to avoid over-spray that can soil passenger clothing. Inspect tires for excessive wear, damage. Test tires
(3) Before applying lubricant, component should be for recommended inflation pressure. Refer to Group
wiped clean. After lubrication, any excess lubricant 22—Tires And Wheels for tire pressure charts, tire
should be removed. replacement, and tread wear indicators.
(4) The hood latch, latch release mechanism, latch
striker and safety latch should be lubricated periodically. ROTATION
(5) The door lock cylinders should be lubricated 2 Tires/wheels should be rotated according to recom-
times each year (preferably autumn and spring): mended interval.
• Spray a small amount of lock cylinder lubricant di- Refer to Group 22—Tires And Wheels for recom-
rectly into lock cylinder mended method of tire/wheel rotation.
• Apply a small amount to key and insert it into
lock cylinder HEADLAMPS
• Rotate it to locked position and then back to un- Every six months check headlamp beams to ensure
locked position several times that headlamp beams are correctly positioned.
• Remove key. Wipe lubricant from it with a clean
cloth to avoid soiling of clothing. AIM ADJUSTMENT
Refer to Group 8L—Lamps for headlamp aim ad-
TIRES justment procedures.
RECOMMENDED MAINTENANCE
SPEEDOMETER CABLE
The condition of tires should be inspected. The in-
flation pressures tested/corrected at same time as en- SERVICE INFORMATION
gine oil is changed and oil filter is replaced. Speedometer cable lubrication is not necessary. For
The tires/wheels should be rotated periodically to en-
service information involving noisy or erratic cables,
sure even tread wear. The tires/wheels should be ro-
refer to Group 8E—Instrument Panel and Gauges.
tated at first 12 000 km (7,500-miles) interval.
Thereafter, at each 24 000 km (15,000-miles) interval.
Z FRONT SUSPENSION AND AXLE 2 - 1

FRONT SUSPENSION AND AXLE

CONTENTS

page page

AXLE NOISE/VIBRATION DIAGNOSIS . . . . . . . . 12 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1

FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . 8 MODEL 30 AXLE AND TUBE AXLE (2WD) . . . . 16
FRONT WHEEL ALIGNMENT . . . . . . . . . . . . . . . . 4 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 40

GENERAL INFORMATION

FRONT SUSPENSION The link/coil suspension allows each wheel to adapt

The Grand Cherokee front suspension is a link/coil to different road surfaces without greatly affecting
design comprised of (Fig. 1); the opposite wheel. Wheels are attached to a hub/
• Drive axle (4WD), tube axle (2WD) bearings which bolts to the knuckles. The hub/bear-
• Track bar ing is not serviceable and is replaced as a unit.
• Stabilizer bar Steering knuckles pivot on replaceable ball studs at-
• Upper and lower suspension arms tached to the axle tube yokes.
The upper and lower suspension arms use bushings
• Coil springs
to isolate road noise. The suspension arms are bolted
• Dual-action shock absorbers
to the frame and axle through the rubber bushings.
• Jounce bumpers (used to limit the travel of the
The lower suspension arm uses cam bolts at the axle
suspension) to allow for caster and pinion angle adjustment. The

Fig. 1 Front Suspension

2 - 2 FRONT SUSPENSION AND AXLE Z

suspension arm travel (jounce or rebound) is limited

through the use of rubber bumpers.
Suspension components which use rubber bushings
should be tightened at vehicle ride height. This will
prevent premature failure of the bushing and main-
tain ride comfort. Bushings must never be lubricated.
The coil springs control ride quality and maintain
proper ride height. The coil springs mount up in the
fender shield which is part of the unitized body
bracket. A rubber doughnut isolator is located be-
tween the top of the spring and the frame. The bot-
tom of the spring seats on a axle pad and is retained
with a clip.
The shock absorbers dampen jounce and rebound of
the vehicle over various road conditions. The top of
the shock absorbers are bolted to the frame. The bot-
tom of the shocks are bolted to the axle spring
bracket.
The stabilizer bar is used to minimize vehicle front
sway during turns. The spring steel bar helps to con-
trol the vehicle body in relationship to the suspen-
sion. The bar extends across the front underside of Fig. 2 Model 30 Differential Cover
the chassis and connects to the frame rails. Links are
• Side gears (splined to the axle shafts) rotate the
connected from the bar to the axle brackets. Stabi-
shafts
lizer bar mounts are isolated by rubber bushings.
During straight-ahead driving, the differential pin-
The track bar is used to minimize front axle side- ion gears do not rotate on the pinion mate shaft. This
to-side movement. The bar is attached to a frame rail occurs because input torque applied to the gears is
bracket with a ball stud and isolated with a bushing divided and distributed equally between the two side
at the axle bracket. gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig. 3).
FRONT DRIVE AXLE When turning corners, the outside wheel must
The integral type housing, has the centerline of the
pinion set below the centerline of the ring gear.
The axles are equipped with A.B.S. brake systems.
The A.B.S. tone rings are pressed onto the axle shaft
near the hub and knuckle. For additional information
on the A.B.S. system refer to Group 5, Brakes.
The Model 30 axle has the assembly part number
and gear ratio listed on a tag. The tag is attached to
the housing cover (Fig. 2). Build date identification
codes are stamped on the axle shaft tube cover side.

STANDARD DIFFERENTIAL OPERATION

The differential gear system divides the torque be-
tween the axle shafts. It allows the axle shafts to ro-
tate at different speeds when turning corners.
Each differential side gear is splined to an axle
shaft. The pinion gears are mounted on a pinion
mate shaft and are free to rotate on the shaft. The Fig. 3 Differential Operation—Straight-Ahead Driving
pinion gear is fitted in a bore in the differential case travel a greater distance than the inside wheel in or-
and is positioned at a right angle to the axle shafts. der to complete a turn. This difference must be com-
In operation, power flow occurs as follows: pensated for in order to prevent the wheels from
• Pinion gear rotates the ring gear scuffing and skidding through the turn. To accom-
• Ring gear (bolted to the differential case) rotates plish this the differential allows the axle shafts to
the case turn at unequal speeds (Fig. 4). In this instance, the
• Differential pinion gears (mounted on the pinion input torque applied to the pinion gears is not di-
mate shaft in the case) rotate the side gears vided equally. The pinion gears now rotate around
Z FRONT SUSPENSION AND AXLE 2 - 3

the pinion mate shaft in opposite directions. This al- ing assemblies are the same as used on the Model 30
lows the side gear and axle shaft attached to the out- drive axle.
side wheel to rotate at a faster speed.

Fig. 4 Differential Operation—On Turns

TUBE AXLE (2WD VEHICLES)
The front axle used on two-wheel drive vehicles is
a one-piece, tubular axle (Fig. 5). The tubular axle
mounts in the same bracketry as does the four-wheel
Fig. 5 Front Axle—2WD Vehicles
drive front axle. The steering knuckles and hub bear-
2 - 4 FRONT SUSPENSION AND AXLE Z

FRONT WHEEL ALIGNMENT

GENERAL INFORMATION (3) Ball studs, steering linkage pivot points and
Front wheel alignment involves the correct posi- steering gear for looseness, roughness, binding or
tioning of the wheels in relation to the vehicle. The wear. Refer to Group 19, Steering for additional in-
positioning is accomplished through suspension and formation.
steering linkage adjustments. An alignment is con- (4) Front wheels for excessive radial, lateral
sidered essential for efficient steering, good direc- runout and unbalance. Refer to Group 22, Wheels
tional stability and to minimize tire wear. The most and Tires for diagnosis information.
important measurements of front end alignment are (5) Suspension components for wear and noise.
caster, camber and toe position. Check components for correct torque. Refer to Groups
Routine inspection of the front suspension 2 and 3, Suspension and Axle for additional informa-
and steering components is a good preventative tion.
maintenance practice. Inspection also helps to
ensure safe operation of the vehicle. ALIGNMENT MEASUREMENTS AND
• CASTER is the forward or rearward tilt of the ADJUSTMENTS
steering knuckle from vertical. Tilting the top of the Before each alignment reading the vehicle should
knuckle rearward provides positive caster. Tilting the be jounced (rear first, then front). Grasp each
top of the knuckle forward provides negative caster. bumper at the center and jounce the vehicle up and
Caster is a directional stability angle which enables down three times. Always release the bumper in the
the front wheels to return to a straight ahead posi- down position.
tion after turns (Fig. 1).
• CAMBER is the inward or outward tilt of the
CAMBER
The wheel camber angle (Fig. 1) is preset at NEG-
wheel relative to the center of the vehicle. Tilting the
ATIVE 0.25 DEGREES (-0.25°). The angle is not ad-
top of the wheel inward provides negative camber.
justable and cannot be altered.
Tilting the top of the wheel outward provides positive
camber. Incorrect camber will cause wear on the in- CASTER
side or outside edge of the tire (Fig. 1). The caster angle (Fig. 1) is set at POSITIVE 7 DE-
• WHEEL TOE POSITION is the difference between GREES (+7°).
the leading inside edges and trailing inside edges of Check the caster of the front axle for correct angle.
the front tires (Fig. 1). Uneven wheel toe position Be sure the axle is not bent or twisted. Road test the
cause’s unstable steering, uneven tire wear and vehicle and observe the steering wheel return-to-cen-
steering wheel off-center. The wheel toe position is ter position. Low caster will cause poor steering
the final front wheel alignment adjustment. wheel returnability.
• STEERING AXIS INCLINATION ANGLE is mea- During the road test, turn the vehicle to both the
sured in degrees. It is the angle that the steering left and right. If the steering wheel returns to the
knuckles are tilted (Fig. 1). The inclination angle has center position unassisted, the caster angle is correct.
a fixed relationship with the camber angle. It will not However, if steering wheel does not return toward
change except when a spindle or ball stud is dam- the center position unassisted, a low caster angle is
aged or bent. The angle is not adjustable and the probable.
damaged component(s) must be replaced to correct Caster can be adjusted by rotating the cams on the
mis-alignment. lower suspension arm (Fig. 2). Changing caster an-
gle will also change the front propeller shaft
CAUTION:Do not attempt to modify any suspension
angle. The propeller shaft angle has priority
or steering component by heating and bending.
over caster. Refer to Group 16, Propeller Shafts
for additional information.
PRE-ALIGNMENT INSPECTION
Before starting a front wheel alignment, the follow- TOE POSITION
ing inspection and necessary corrections must be The wheel toe position adjustment should be the fi-
completed. nal adjustment.
(1) Tires with the same recommended air pressure, (1) Start the engine and turn wheels both ways be-
size, and tread wear. Refer to Group 22, Wheels and fore straightening the wheels. Secure the steering
Tires for diagnosis information. wheel with the front wheels in the straight-ahead po-
sition.
(2) Front wheel bearings for wear.
(2) Loosen the adjustment sleeve clamp bolts (Fig.
3).
Z FRONT SUSPENSION AND AXLE 2 - 5

Fig. 1 Wheel Alignment Measurements

(3) Adjust the right wheel toe position with the

drag link. Turn the sleeve until the right wheel is at
positive 0.12 degrees (0.12°) TOE-IN position. Posi-
tion the clamp bolts as shown (Fig. 4) and tighten to
49 Nzm (36 ft. lbs.) torque. Make sure the toe set-
ting does not change during clamp tightening.
(4) Adjust the left wheel toe position with the tie
rod. Turn the sleeve until the left wheel is at positive
0.12 degrees (0.12°) TOE-IN position. Position the
clamp bolts as shown (Fig. 4) and tighten to 27 Nzm
(20 ft. lbs.) torque. Make sure the toe setting does
not change during clamp tightening.
(5) Verify the right toe setting.

Fig. 2 Cam Adjuster

2 - 6 FRONT SUSPENSION AND AXLE Z

SUSPENSION AND STEERING SYSTEM DIAGNOSIS

Z FRONT SUSPENSION AND AXLE 2 - 7

Fig. 3 Steering Linkage

ALIGNMENT SPECIFICATIONS

Fig. 4 Drag Link and Tie Rod Clamp Location

2 - 8 FRONT SUSPENSION AND AXLE Z

FRONT SUSPENSION

INDEX
page page

Axle Bushing Replacement . . . . . . . . . . . . . . . . . . . 9 Spring and Shock Diagnosis . . . . . . . . . . . . . . . . . 10

Coil Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Stabilizer Bar . . . . . . . . . . . .................. 8
Lower Suspension Arm . . . . . . . . . . . . . . . . . . . . . 10 Track Bar . . . . . . . . . . . . . . .................. 8
Service Information . . . . . . . . . . . . . . . . . . . . . . . . . 8 Upper Suspension Arm . . . . .................. 8
Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SERVICE INFORMATION
CAUTION: Suspension components that use rubber
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
fasteners are torqued. If the springs are not at their
normal ride position, vehicle ride comfort could be
affected. Rubber bushings must never be lubri-
cated.

TRACK BAR
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the cotter pin and nut from the ball
stud end at the frame rail bracket (Fig. 1).
A puller tool may be necessary to separate the
ball stud from the frame rail bracket.
(3) Remove the bolt and flag nut from the axle
shaft tube bracket (Fig. 1). Remove the track bar.

INSTALLATION
(1) Install the track bar at axle tube bracket.
Loosely install the retaining bolt and flag nut (Fig.
1).
(2) It may be necessary to pry the axle assembly
Fig. 1 Track Bar
over to install the track bar at the frame rail. Install
track bar at the frame rail bracket (Fig. 1). Install INSTALLATION
the retaining nut on the stud. (1) Position the stabilizer bar on the frame rail and
(3) Remove the supports and lower the vehicle. install the clamps and bolts. Ensure the bar is cen-
(4) Tighten the bolt at the axle shaft tube bracket tered with equal spacing on both sides. Tighten the
to 75 Nzm (55 ft. lbs.) torque. bolts to 54 Nzm (40 ft. lbs.).
(5) Tighten the ball stud nut to 81 Nzm (60 ft. lbs.) (2) Install the links and grommets onto the stabi-
torque. Install a new cotter pin. lizer bar and axle brackets (Fig. 2). Tighten the nut
at the connecting links at the axle bracket to 95 Nzm
STABILIZER BAR (70 ft. lbs.) torque.
(3) Tighten the stabilizer bar to connecting link
REMOVAL nut to 36 Nzm (27 ft. lbs.) torque.
(1) Raise and support the vehicle. (4) Remove the supports and lower the vehicle.
(2) Disconnect the stabilizer bar links from the
axle brackets (Fig. 2). UPPER SUSPENSION ARM
(3) Disconnect the stabilizer bar from the links.
(4) Disconnect the stabilizer bar clamps from the REMOVAL
frame rails. Remove the stabilizer bar. (1) Raise and support the vehicle.
Z FRONT SUSPENSION AND AXLE 2 - 9

INSTALLATION
(1) Position the upper suspension arm at the axle
and frame rail (Fig. 3).
(2) Install the bolts and finger tighten the nuts
(Fig. 3).
(3) Remove the supports and lower the vehicle.
(4) Tighten the nut at the axle and frame bracket
to 75 Nzm (55 ft. lbs.) torque.

AXLE BUSHING REPLACEMENT

(1) Remove the upper suspension arm from axle.
Refer to Upper Suspension Arm Removal in this
Group.
(2) Insert Spacer 7932-3 (J-35581-3) around the
bushing in the axle bracket ears (Fig. 4).
(3) Assemble and install Bushing Removal/Install-
er (Fig. 4).
(4) Remove the bushing by tightening the hex-head
on Long Nut.
For two-wheel drive axles and right side on
Model 30 axle, do not remove Spacer 7932-3 (J-
Fig. 2 Stabilizer Bar 35581-3) at this time.
(5) Position the new bushing on Installer.
(2) Remove the upper suspension arm nut and bolt (6) Install the bushing by tightening the hex-head
at the axle bracket (Fig. 3). on Long Nut (Fig. 5). Remove Spacer 7932-3 (J-
(3) Remove the nut and bolt (Fig. 3) at the frame 35581-3).
rail and remove the upper suspension arm. (7) Install the upper suspension arm to axle. Refer
to Upper Suspension Arm Installation in this Group.

Fig. 3 Upper and Lower Suspension Arms

2 - 10 FRONT SUSPENSION AND AXLE Z

Fig. 4 Axle Bracket Bushing Removal

Fig. 6 Cam Adjuster
INSTALLATION
(1) Position the lower suspension arm at the axle
bracket and frame rail bracket.
(2) Install the rear bolts and finger tighten the
nuts (Fig. 6).
(3) Install the cam bolt, cam and nut in the axle.
Re-align the reference marks.
(4) Install the bolts and finger tighten the nuts
(Fig. 6).
(5) Lower the vehicle.
(6) Tighten the front and rear nuts to 176 Nzm
(130 ft. lbs.) torque.

SPRING AND SHOCK DIAGNOSIS

A squeak noise from the shock absorber can be pro-
duced if movement between the rubber bushings and
the metal occurs. This noise can usually be stopped
by tightening the attaching nuts. If the squeak noise
persists, inspect for damaged and worn bushings,
and attaching components. Repair as necessary.
The shock absorbers are not refillable or adjust-
Fig. 5 Axle Bracket Bushing Installation able. If a malfunction occurs, the shock absorber
LOWER SUSPENSION ARM must be replaced. To test a shock absorber, hold it in
an upright position and force the piston into and out
REMOVAL of the cylinder four or five times. The action through-
(1) Raise and support the vehicle. out each stroke should be smooth and even.
(2) Paint or scribe alignment marks on the cam ad-
justers and suspension arm for installation reference SHOCK ABSORBER
(Fig. 6).
(3) Remove the lower suspension arm nut, cam REMOVAL
and cam bolt from the axle (Fig. 3). (1) Remove the nut, retainer and grommet from
(4) Remove the nut and bolt from the frame rail the upper stud in the engine compartment (Fig. 7).
bracket and remove the lower suspension arm (Fig. (2) Remove the lower nuts and bolts from the axle
6). bracket (Fig. 7). Remove the shock absorber.
Z FRONT SUSPENSION AND AXLE 2 - 11

(2) Paint or scribe alignment marks on the cam ad-

justers and axle bracket for installation reference
(Fig. 6).
(3) Mark and disconnect the front propeller shaft
from the axle.
(4) Remove the lower suspension arm nut, cam
and cam bolt from the axle (Fig. 3).
(5) Disconnect the stabilizer bar link and shock ab-
sorber from the axle.
(6) Disconnect the track bar from the frame rail
bracket.
(7) Disconnect the drag link from the pitman arm.
(8) Lower the axle until the spring is free from the
upper mount. Remove the coil spring retainer bolt
and remove the spring.
(9) Remove the jounce bumper if necessary from
the upper spring mount (Fig. 7).

INSTALLATION
(1) Install the jounce bumper on the upper spring
mount. Tighten the bolts to 42 Nzm (31 ft. lbs.)
torque (Fig. 7).
(2) Position the coil spring on the axle pad. Install
the spring retainer and bolt.
(3) Raise the axle into position until the spring
seats in the upper mount.
(4) Connect the stabilizer bar links and shock ab-
Fig. 7 Coil Spring & Shock Absorber sorbers to the axle bracket. Connect the track bar to
the frame rail bracket.
INSTALLATION (5) Install the lower suspension arm to the axle.
(1) Position the lower retainer and grommet on the (6) Install the front propeller shaft to the axle.
upper stud. Insert the shock absorber through the (7) Install drag link to pit man arm.
shock tower hole. (8) Remove the supports and lower the vehicle.
(2) Install the lower bolts and nuts. Tighten nuts (9) Tighten all suspension components to proper
to 27 Nzm (20 ft. lbs.) torque. torque.
(3) Install the upper grommet and retainer on the
stud in the engine compartment. Install the nut and
tighten to 23 Nzm (17 ft. lbs.) torque.

COIL SPRING
REMOVAL
(1) Raise and support the vehicle. Position a hy-
draulic jack under the axle to support it.
2 - 12 FRONT SUSPENSION AND AXLE Z

AXLE NOISE/VIBRATION DIAGNOSIS

INDEX
page page

Driveline Snap . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Low Speed Knock . . . . . . . . . . . . . . . . . . . . . . . . . 13

Gear and Bearing Noise . . . . . . . . . . . . . . . . . . . . 12 Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General Information . . . . . . . . . . . . . . . . . . . . . . . 12

GENERAL INFORMATION Excessive bearing preload may not be noisy. This

Axle bearing problem conditions are usually caused condition will cause high temperature which can re-
by: sult in bearing failure.
• Insufficient or incorrect lubricant
• Foreign matter/water contamination GEAR AND BEARING NOISE
• Incorrect bearing preload torque adjustment GEAR NOISE
• Incorrect backlash ( to tight) Axle gear noise can be caused by insufficient lubri-
When serviced, the bearings must be cleaned thor- cant. Incorrect backlash, tooth contact, or worn/dam-
oughly. They should be dried with lint-free shop tow- aged gears can cause noise.
els. Never dry bearings with compressed air. Gear noise usually happens at a specific speed
This will overheat them and brinell the bearing range. The range is 30 to 40 mph, or above 50 mph.
surfaces. This will result in noisy operation af- The noise can also occur during a specific type of
ter repair. driving condition. These conditions are acceleration,
Axle gear problem conditions are usually the result deceleration, coast, or constant load.
of: When road testing, accelerate the vehicle to the
• Insufficient lubrication speed range where the noise is the greatest. Shift
• Incorrect or contaminated lubricant out-of-gear and coast through the peak-noise range.
• Overloading (excessive engine torque) If the noise stops or changes greatly, check for insuf-
• Exceeding vehicle weight capacity ficient lubricant. Incorrect ring gear backlash, or
• Incorrect clearance or backlash adjustment gear damage can cause noise changes.
Insufficient lubrication is usually the result of a Differential side and pinion gears can be checked
housing cover leak. It can also be from worn axle by turning the vehicle. They usually do not cause
shaft or pinion gear seals. Check for cracks or porous noise in straight-ahead driving. These gears are
areas in the housing or tubes. loaded during vehicle turns. If noise does occur dur-
Using the wrong lubricant will cause overheating ing vehicle turns, the side or pinion gears could be
and gear failure. Gear tooth cracking and bearing worn or damaged. A worn pinion gear mate shaft can
spalling are indicators of this. also cause a snapping or a knocking noise.
Axle component breakage is most often the result
of: BEARING NOISE
• Severe overloading The axle shaft, differential and pinion gear bearings
• Insufficient lubricant can all produce noise when worn or damaged. Bearing
• Incorrect lubricant noise can be either a whining, or a growling sound.
• Improperly tightened components Pinion gear bearings have a constant-pitch noise.
Common causes of overloading is from full-throttle This noise changes only with vehicle speed. Pinion
acceleration. Overloading happens when towing bearing noise will be higher because it rotates at a
heavier-than-recommended loads. Component break- faster rate. Drive the vehicle and load the differen-
age can occur when the wheels are spun excessively. tial. If bearing noise occurs the pinion rear bearing is
Insufficient or incorrect lubricants contribute to the source of the noise. If the bearing noise is heard
breakage through overheating. Loose differential during a coast, front bearing is the source.
components can also cause breakage. Worn, damaged differential bearings usually pro-
Incorrect bearing preload or gear backlash will not duce a low pitch noise. Differential bearing noise is
result in component breakage. This will cause acceler- similar to pinion bearing. The pitch of differential
ated wear and contribute to early failure. Mis-adjust- bearing noise is also constant and varies only with
ment will produce noise. If a mis-adjustment condition vehicle speed.
is not corrected, component failure can result. Axle shaft bearings produce noise and vibration
when worn or damaged. The noise generally changes
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