2002 Jeep Grand Cherokee Service Repair Manual by 163215

JEEPT SERVICE MANUAL

2002 WG GRAND CHEROKEE

NO PART OF THIS PUBLICATION MAY BE REPRODUCED, STORED IN A RETRIEVAL SYSTEM, OR TRANSMITTED, IN ANY FORM OR BY ANY MEANS, ELECTRONIC, MECHANICAL, PHOTOCOPYING, RECORDING, OR OTHERWISE, WITHOUT THE PRIOR WRITTEN PERMISSION OF DAIMLERCHRYSLER CORPORATION.

DaimlerChrysler Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products previously manufactured.

FOREWORD

The information contained in this service manual has been prepared for the professional automotive technician involved in daily repair operations. Information describing the operation and use of standard and optional equipment is included in the Ownerâ&#x20AC;&#x2122;s Manual provided with the vehicle. Information in this manual is divided into groups. These groups contain description, operation, diagnosis, testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and components. To assist in locating a group title page, use the Group Tab Locator by clicking to the following page. The first page of the group has a contents section that lists major topics within the group. A Service Manual Comment form is included at the rear of this manual. Use the form to provide DaimlerChrysler 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 replacing fasteners, always use the same type (part number) fastener as removed. DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair methods, or vehicle wiring at any time without prior notice or incurring obligation.

GROUP TAB LOCATOR Introduction

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

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

Service Manual Comment Forms

(Rear of Manual)

INTRODUCTION

INTRODUCTION TABLE OF CONTENTS page BODY CODE PLATE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . FASTENER IDENTIFICATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . FASTENER USAGE DESCRIPTION - FASTENER USAGE . . . . . THREADED HOLE REPAIR DESCRIPTION - THREADED HOLE REPAIR INTERNATIONAL SYMBOLS DESCRIPTION - INTERNATIONAL SYMBOLS METRIC SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . .

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

page TORQUE REFERENCES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . VEHICLE EMISSION CONTROL INFORMATION (VECI) DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . VEHICLE SAFETY CERTIFICATION LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . .

...7

...8 ...8 ...9

...4 ....5

BODY CODE PLATE

FASTENER IDENTIFICATION

DESCRIPTION

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

The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus 2. The most commonly used metric bolt strength classes are 9.8 and 10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut face. Refer to the Fastener Identification and Fastener Strength Charts (Fig. 2) and (Fig. 3).

Fig. 1 Body Code Plate

INTRODUCTION

FASTENER IDENTIFICATION (Continued)

Fig. 2 FASTENER IDENTIFICATION

INTRODUCTION

WJ FASTENER IDENTIFICATION (Continued)

Fig. 3 FASTENER STRENGTH

INTRODUCTION

FASTENER USAGE

THREADED HOLE REPAIR

DESCRIPTION - FASTENER USAGE

DESCRIPTION - THREADED HOLE REPAIR

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

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

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

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

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

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

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

INTRODUCTION

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

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

CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY

TO GET

MULTIPLY

TO GET

in-lbs

x 0.11298

= Newton Meters (N·m)

N·m

x 8.851

= in-lbs

ft-lbs

x 1.3558

= Newton Meters (N·m)

N·m

x 0.7376

= ft-lbs

Inches Hg (60° F)

x 3.377

= Kilopascals (kPa)

kPa

x 0.2961

= Inches Hg

psi

x 6.895

= Kilopascals (kPa)

kPa

x 0.145

= psi

Inches

x 25.4

= Millimeters (mm)

x 0.03937

= Inches

Feet

x 0.3048

= Meters (M)

x 3.281

= Feet

Yards

x 0.9144

= Meters

x 1.0936

= Yards

mph

x 1.6093

= Kilometers/Hr. (Km/h)

Km/h

x 0.6214

= mph

Feet/Sec

x 0.3048

= Meters/Sec (M/S)

M/S

x 3.281

= Feet/Sec

mph

x 0.4470

= Meters/Sec (M/S)

M/S

x 2.237

= mph

Kilometers/Hr. (Km/h)

x 0.27778

= Meters/Sec (M/S)

M/S

x 3.600

Kilometers/Hr. (Km/h)

COMMON METRIC EQUIVALENTS 1 inch = 25 Millimeters

1 Cubic Inch = 16 Cubic Centimeters

1 Foot = 0.3 Meter

1 Cubic Foot = 0.03 Cubic Meter

1 Yard = 0.9 Meter

1 Cubic Yard = 0.8 Cubic Meter

1 Mile = 1.6 Kilometers Refer to the Metric Conversion Chart to convert torque values listed in metric Newton- meters (N·m). Also, use the chart to convert between millimeters (mm) and inches (in.) (Fig. 4).

INTRODUCTION

METRIC SYSTEM (Continued)

Fig. 4 METRIC CONVERSION CHART

INTRODUCTION

TORQUE REFERENCES

tions Chart for torque references not listed in the individual torque charts (Fig. 5).

DESCRIPTION Individual Torque Charts appear within many or the Groups. Refer to the Standard Torque Specifica-

Fig. 5 TORQUE SPECIFICATIONS

INTRODUCTION

VEHICLE EMISSION CONTROL INFORMATION (VECI) DESCRIPTION All vehicles are equipped with a combined vehicle emission control information (VECI) label(s). The label is located in the engine compartment on the vehicle hood (Fig. 6). Two labels are used for vehicles built for sale in the country of Canada. The VECI label(s) contain the following: • Engine family and displacement • Evaporative family • Emission control system schematic • Certification application • Spark plug and gap The label also contains an engine vacuum schematic. There are unique labels for vehicles built for sale in the state of California and the country of Canada. Canadian labels are written in both the English and French languages. These labels are permanently attached and cannot be removed without defacing information and destroying label.

VEHICLE IDENTIFICATION NUMBER DESCRIPTION

Fig. 6 VECI Label Location 1 - VECI LABEL (CANADIAN) 2 - VECI LABEL 3 - HOOD

The VIN contains 17 characters that provide data concerning the vehicle. Refer to the decoding chart to determine the identification of a vehicle.

The Vehicle Identification Number (VIN) plate is attached to the top left side of the instrument panel.

VEHICLE IDENTIFICATION NUMBER DECODING CHART POSITION

INTERPRETATION

CODE = DESCRIPTION

Country of Origin

1 = United States

Make

J = Jeep

Vehicle Type

4 = MPV

Gross Vehicle Weight Rating

G = 5001-6000 lbs.

Vehicle Line

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

Series

3 = Sport 4 = Laredo 5 = Limited 6 = Overland

Body Style

8 = 4dr Sport Utility

Engine

S = 4.0 Liter Gasoline N = 4.7 Liter Gasoline

Check Digit

0 through 9 or X

Model Year

2=2002

Assembly Plant

C = Jefferson Assembly

12 thru 17

Vehicle Build Sequence

VEHICLE SAFETY CERTIFICATION LABEL

INTRODUCTION

The label is located on the driver-side door shut-face.

DESCRIPTION A vehicle safety certification label (Fig. 7) is attached to every DaimlerChrysler Corporation vehicle. The label certifies that the vehicle conforms to all applicable Federal Motor Vehicle Safety Standards. The label also lists: • Month and year of vehicle manufacture. • Gross Vehicle Weight Rating (GVWR). The gross front and rear axle weight ratings (GAWR’s) are based on a minimum rim size and maximum cold tire inflation pressure. • Vehicle Identification Number (VIN). • Type of vehicle. • Type of rear wheels. • Bar code. • Month, Day and Hour (MDH) of final assembly. • Paint and Trim codes. • Country of origin.

Fig. 7 VEHICLE SAFETY CERTIFICATION LABEL TYPICAL

LUBRICATION & MAINTENANCE

0-1

LUBRICATION & MAINTENANCE TABLE OF CONTENTS page LUBRICATION & MAINTENANCE SPECIFICATIONS - FLUID CAPACITIES . . . . INTERNATIONAL SYMBOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . PARTS & LUBRICANT RECOMMENDATION STANDARD PROCEDURE - PARTS & LUBRICANT RECOMMENDATIONS . . . . . . FLUID TYPES DESCRIPTION DESCRIPTION - ENGINE COOLANT . . . . . DESCRIPTION - ENGINE COOLANT . . . . . ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . DESCRIPTION - ENGINE OIL . . . . . . . . . . DESCRIPTION ..................... DESCRIPTION - TRANSFER CASE - NV242 DESCRIPTION - TRANSFER CASE - NV247 DESCRIPTION - AUTOMATIC TRANSMISSION FLUID . . . . . . . . . . . . . . . DESCRIPTION - ENGINE OIL - DIESEL ENGINES . . . . . . . . . . . . . . . . . . . . . . . . .

...1 ...2

...2

. . . . .

. . . . . . .

OPERATION - AUTOMATIC TRANSMISSION FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLUID FILL/CHECK LOCATIONS INSPECTION - FLUID FILL/CHECK LOCATIONS ....................... MAINTENANCE SCHEDULES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . LIFT POINTS STANDARD PROCEDURE - HOISTING AND JACKING RECOMMENDATIONS . . . . . . . . JUMP STARTING STANDARD PROCEDURE - JUMP STARTING EMERGENCY TOW HOOKS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . TOWING STANDARD PROCEDURE - TOWING RECOMMENDATIONS . . . . . . . . . . . . . . . .

...6

...6 ...6

...6 ..7 ...8

...8

...5 ...6

LUBRICATION & MAINTENANCE SPECIFICATIONS - FLUID CAPACITIES DESCRIPTION

SPECIFICATION

FUEL TANK

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

Engine Oil - with Filter 2.7L Diesel

6.5L (6.9 qts.)

Engine Oil - with Filter 4.0L

5.7 L (6.0 qts.)

Engine Oil - with Filter 4.7L

5.7 L (6.0 qts.)

Cooling System - 2.7L Diesel

14.2L (15 qts.)***

Cooling System - 4.0L

14.1 L (15 qts.)***

Cooling System - 4.7L

.2 .3 .4 .4 .5 .5 .5

page

13.7 L (14.5 qts.)***

AUTOMATIC TRANSMISSION

DESCRIPTION

SPECIFICATION

O-haul Fill - 545RFE

13.33 L (28.0 pts.)

Dry fill capacity Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these figures may vary. (Refer to appropriate 21 - TRANSMISSION/TRANSAXLE/ AUTOMATIC/FLUID - STANDARD PROCEDURE). TRANSFER CASE NV242

1.35L (2.85 pts.)

NV247

1.6L (3.4 pts.)

FRONT AXLE ± 0.3 L (1 oz.) 186 FBI (Model 30)

1.18 L (2.5 pts.)*

* With Vari-Lok add 0.07 L (2.5 oz.) of Friction Modifier. REAR AXLE ± 0.3 L (1 oz.) 198 RBI (Model 35)

1.66 L (3.5 pts.)*

226 RBA (Model 44)

2.24 L (4.75 pts.)**

* With Trac-lok add 0.07 L (2.5 oz.) of Friction Modifier. ** With Trac-lok or Vari-Lok, add 0.07 L (2.5 oz.) of Friction Modifier.

Service Fill - 42RE

3.8 L (4.0 qts.)

Service Fill - 545RFE

2WD - 5.2 L (11 pts.)

*** Includes 0.9L (1.0 qts.) for coolant reservoir.

4WD - 6.2 L (13 pts.)

****Nominal refill capacities are shown. A variation may be observed from vehicle to vehicle due to manufacturing tolerance and refill procedure.

O-haul Fill - 42RE

9.1-9.5 L (19-20 pts.)

0-2

LUBRICATION & MAINTENANCE

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

FLUID TYPES DESCRIPTION DESCRIPTION - ENGINE COOLANT ETHYLENE-GLYCOL MIXTURES CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol.

Fig. 1 INTERNATIONAL SYMBOLS

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

The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide protection against freezing to -37 deg. C (-35 deg. F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7 deg. C (-90 deg. F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149 deg. C (300) deg. F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22 deg. C (-8 deg. F ).

PROPYLENE-GLYCOL MIXTURES

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

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

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

LUBRICATION & MAINTENANCE

0-3

FLUID TYPES (Continued) Propylene-glycol/ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene glycol.

DESCRIPTION - ENGINE COOLANT WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. CAUTION: Use of Propylene Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopart Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution.

CAUTION: MoparT Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection.

COOLANT PERFORMANCE The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water-Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol-The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water-Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, yearround in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol.

COOLANT SELECTION AND ADDITIVES The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopart Antifreeze/Coolant, 5 Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain to obtain a freeze point of -37°C (-35°F). If it loses color or

0-4

LUBRICATION & MAINTENANCE

FLUID TYPES (Continued) becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Do not use coolant additives that are claimed to improve engine cooling.

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

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

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

Fig. 4 API SYMBOL

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

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

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

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

SAE VISCOSITY

Fig. 3 Temperature/Engine Oil Viscosity - 4.7L

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

LUBRICATION & MAINTENANCE

0-5

FLUID TYPES (Continued)

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

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

DESCRIPTION - AUTOMATIC TRANSMISSION FLUID Fig. 5 Temperature/Engine Oil Viscosity - 4.0L

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

NOTE: Refer to Service Procedures in this group for fluid level checking procedures. Mopart ATF +4, type 9602, Automatic Transmission Fluid is the recommended fluid for DaimlerChrysler automatic transmissions. Dexron II fluid IS NOT recommended. Clutch chatter can result from the use of improper fluid. Mopart ATF +4, type 9602, Automatic Transmission Fluid when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change.

FLUID ADDITIVES Fig. 6 API Symbol

DESCRIPTION A multi-purpose, hypoid gear lubricant which conforms to MIL-L-2105C and API GL 5 quality specifications should be used. Mopar Hypoid Gear Lubricant conforms to these specifications.

FRONT AXLE • Lubricant is SAE 75W-140 SYNTHETIC. REAR AXLE • Lubricant is a thermally stable SAE 80W-90 gear lubricant. • Lubricant for heavy-duty or trailer tow use is SAE 75W-140 SYNTHETIC. NOTE: Trac-lokT and Vari-lokT equipped axles require a friction modifier be added to the lubricant.

DaimlerChrysler strongly recommends against the addition of any fluids to the transmission, other than those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks. Various “special” additives and supplements exist that claim to improve shift feel and/or quality. These additives and others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge. These claims have not been supported to the satisfaction of DaimlerChrysler and these additives must not be used. The use of transmission “sealers” should also be avoided, since they may adversely affect the integrity of transmission seals.

0-6

LUBRICATION & MAINTENANCE

FLUID TYPES (Continued)

DESCRIPTION - ENGINE OIL - DIESEL ENGINES Use only Diesel Engine Oil meeting standard MIL2104C or API Classification CD or higher or CCML D4, D5.

MAINTENANCE SCHEDULES DESCRIPTION 9Maintenance Schedule Information not included in this section, is located in the appropriate Owner’s Manual.9

SAE VISCOSITY GRADE CAUTION: Low viscosity oils must have the proper API quality or the CCMC G5 designation. To assure of properly formulated engine oils, it is recommended that SAE Grade 10W-40 engine oils that meet Chrysler material standard MS-6395, be used. European Grade 10W-40 oils are also acceptable. Oils of the SAE 5W-40 or 8W-80 grade number are preferred when minimum temperatures consistently fall below -12°C.

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

FLUID FILL/CHECK LOCATIONS

LIFT POINTS STANDARD PROCEDURE - HOISTING AND JACKING RECOMMENDATIONS FLOOR JACK When properly positioned, a floor jack can be used to lift a WJ vehicle (Fig. 7). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. CAUTION: Do not attempt to lift a vehicle with a floor jack positioned under: • An axle tube. • Aluminum differential. • A body side sill. • A steering linkage component. • A drive shaft. • The engine or transmission oil pan. • The fuel tank. • A front suspension arm.

HOIST A • • •

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

NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (Fig. 7).

INSPECTION - FLUID FILL/CHECK LOCATIONS The fluid fill/check locations and lubrication points are located in each applicable group.

WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVETRAIN COMPONENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST.

LUBRICATION & MAINTENANCE

0-7

LIFT POINTS (Continued)

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

Fig. 7 Correct Vehicle Lifting Locations

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

(2) When using another vehicle as a booster source, park the booster vehicle within cable reach. Turn off all accessories, set the parking brake, place the automatic transmission in PARK or the manual transmission in NEUTRAL and turn the ignition OFF. (3) On disabled vehicle, place gear selector in park or neutral and set park brake. Turn off all accessories. (4) Connect jumper cables to booster battery. RED clamp to positive terminal (+). BLACK clamp to negative terminal (-). DO NOT allow clamps at opposite end of cables to touch, electrical arc will result. Review all warnings in this procedure. (5) On disabled vehicle, connect RED jumper cable clamp to positive (+) terminal. Connect BLACK jumper cable clamp to engine ground as close to the ground cable attaching point as possible (Fig. 8). (6) Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the engine in the vehicle with the discharged battery. CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will overheat and could fail. (7) Allow battery in disabled vehicle to charge to at least 12.4 volts (75% charge) before attempting to start engine. If engine does not start within 15 seconds, stop cranking engine and allow starter to cool (15 min.), before cranking again.

0-8

LUBRICATION & MAINTENANCE

JUMP STARTING (Continued)

Fig. 8 Jumper Cable Clamp Connections 1 2 3 4 5 6 7

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

DISCONNECT CABLE CLAMPS AS FOLLOWS: • Disconnect BLACK cable clamp from engine ground on disabled vehicle. • When using a Booster vehicle, disconnect BLACK cable clamp from battery negative terminal. Disconnect RED cable clamp from battery positive terminal. • Disconnect RED cable clamp from battery positive terminal on disabled vehicle.

Fig. 9 Emergency Tow Hooks 1 - TOW HOOK

TOWING STANDARD PROCEDURE - TOWING RECOMMENDATIONS A vehicle equipped with SAE approved wheel lifttype towing equipment can be used to tow WJ vehicles. When towing a 4WD vehicle using a wheel-lift towing device, use tow dollies under the opposite end of the vehicle. A vehicle with flatbed device can also be used to transport a disabled vehicle (Fig. 10).

EMERGENCY TOW HOOKS DESCRIPTION WARNING: REMAIN AT A SAFE DISTANCE FROM A VEHICLE THAT IS BEING TOWED VIA ITS TOW HOOKS. THE TOW STRAPS/CHAINS COULD BREAK AND CAUSE SERIOUS INJURY. Some Jeep vehicles are equipped with front emergency tow hooks (Fig. 9). The tow hooks should be used for EMERGENCYpurposes only. CAUTION: DO NOT use emergency tow hooks for tow truck hook-up or highway towing.

Fig. 10 Tow Vehicles With Approved Equipment

SAFETY PRECAUTIONS CAUTION: The following safety precautions must be observed when towing a vehicle: • Secure loose and protruding parts. • Always use a safety chain system that is independent of the lifting and towing equipment.

LUBRICATION & MAINTENANCE

0-9

TOWING (Continued) • Do not allow towing equipment to contact the disabled vehicle’s fuel tank. • Do not allow anyone under the disabled vehicle while it is lifted by the towing device. • Do not allow passengers to ride in a vehicle being towed. • Always observe state and local laws regarding towing regulations. • Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians or other motorists. • Do not attach tow chains, T-hooks, or J-hooks to a bumper, steering linkage, drive shafts or a non-reinforced frame hole. • Do not tow a heavily loaded vehicle. Use a flatbed device to transport a loaded vehicle.

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

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

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

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

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

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

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

0 - 10

LUBRICATION & MAINTENANCE

TOWING (Continued) (6) Turn the ignition switch to the OFF position to unlock the steering wheel. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. (7) Secure steering wheel in straight ahead position with a clamp device designed for towing. (8) Place transmission in park.

FOUR WHEEL DRIVE TOWINGâ&#x20AC;&#x201D;FRONT END LIFTED WARNING: ENSURE VEHICLE IS ON A LEVEL SURFACE OR THE WHEELS ARE BLOCKED TO PREVENT VEHICLE FROM ROLLING. (1) Attach wheel lift device to rear wheels.

(2) Place the transmission in neutral. (3) Raise the rear of the vehicle off the ground and install tow dollies under rear wheels. (4) Attach wheel lift device to front wheels and raise vehicle to towing position. (5) Attach the safety chains. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. (6) Turn the ignition switch to the OFF position to unlock the steering wheel. (7) Secure steering wheel in straight ahead position with a clamp device designed for towing. (8) Place transmission in park.

SUSPENSION

2-1

SUSPENSION TABLE OF CONTENTS page

page

SUSPENSION DIAGNOSIS AND TESTING - SUSPENSION AND STEERING SYSTEM . . . . . . . . . . . . . . . . 1

WHEEL ALIGNMENT ......................3 FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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

EXCESSIVE PLAY IN STEERING

FRONT WHEELS SHIMMY

VEHICLE INSTABILITY

EXCESSIVE STEERING EFFORT

POSSIBLE CAUSES

CORRECTION

1. Loose or worn wheel bearings.

1. Adjust or replace wheel bearings.

2. Loose or worn steering or suspension components.

2. Tighten or replace components as necessary.

1. Loose or worn wheel bearings.

1. Adjust or replace wheel bearings.

2. Loose or worn steering or suspension components.

2. Tighten or replace components as necessary.

3. Loose or worn steering gear.

3. Adjust or replace steering gear.

1. Loose or worn wheel bearings.

1. Adjust or replace wheel bearings.

2. Loose or worn steering or suspension components.

2. Tighten or replace components as necessary.

3. Tires worn or out of balance.

3. Replace or balance tires.

4. Alignment.

4. Align vehicle to specifications.

5. Leaking steering dampener.

5. Replace steering dampener.

1. Loose or worn wheel bearings.

1. Adjust or replace wheel bearings.

2. Loose or worn steering or suspension components.

2. Tighten or replace components as necessary.

3. Tire pressure.

3. Adjust tire pressure.

4. Alignment.

4. Align vehicle to specifications.

1. Loose or worn steering gear.

1. Adjust or replace steering gear.

2. Power steering fluid low.

2. Add fluid and repair leak.

3. Column coupler binding.

3. Replace coupler.

4. Tire pressure.

4. Adjust tire pressure.

5. Alignment.

5. Align vehicle to specifications.

2-2

SUSPENSION

SUSPENSION (Continued) CONDITION VEHICLE PULLS TO ONE SIDE DURING BRAKING

VEHICLE LEADS OR DRIFTS FROM STRAIGHT AHEAD DIRECTION ON UNCROWNED ROAD

KNOCKING, RATTLING OR SQUEAKING

IMPROPER TRACKING

POSSIBLE CAUSES 1. Uneven tire pressure.

CORRECTION 1. Adjust tire pressure.

2. Worn brake components.

2. Repair brakes as necessary.

3. Air in brake line.

3. Repair as necessary.

1. Radial tire lead.

1. Cross front tires.

2. Brakes dragging.

2. Repair brake as necessary.

3. Weak or broken spring.

3. Replace spring.

4. Uneven tire pressure.

4. Adjust tire pressure.

5. Wheel Alignment.

5. Align vehicle.

6. Loose or worn steering or suspension components.

6. Repair as necessary.

7. Cross caster out of spec.

7. Align vehicle.

1. Worn shock bushings.

1. Replace shock.

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

2. Inspect, tighten or replace components as necessary.

3. Shock valve.

3. Replace shock.

1. Loose, worn or bent track bar.

1. Inspect, tighten or replace component as necessary.

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

2. Inspect, tighten or replace components as necessary.

WHEEL ALIGNMENT

2-3

WHEEL ALIGNMENT TABLE OF CONTENTS page

page

WHEEL ALIGNMENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 STANDARD PROCEDURE STANDARD PROCEDURE - CAMBER . . . . . . . 3

STANDARD PROCEDURE - CASTER . . . . . . . 4 STANDARD PROCEDURE - TOE POSITION . . 4 SPECIFICATIONS ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

OPERATION • CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle rearward provides positive caster. Tilting the top of the knuckle forward provides negative caster. Caster is a directional stability angle. This angle enables the front wheels to return to a straight ahead position after turns (Fig. 1). • CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the

inside or outside edge of the tire. The angle is not adjustable, damaged component(s) must be replaced to correct the camber angle (Fig. 1). • WHEEL TOE POSITION is the difference between the leading inside edges and trailing inside edges of the front tires. Incorrect wheel toe position is the most common cause of unstable steering and uneven tire wear. The wheel toe position is the final front wheel alignment adjustment (Fig. 1). • STEERING AXIS INCLINATION ANGLE is measured in degrees and is the angle that the steering knuckles are tilted. The inclination angle has a fixed relationship with the camber angle. It will not change except when a spindle or ball stud is damaged or bent. The angle is not adjustable, damaged component(s) must be replaced to correct the steering axis inclination angle. • THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle (Fig. 1).

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

2-4

WHEEL ALIGNMENT

WHEEL ALIGNMENT (Continued)

Fig. 1 Wheel Alignment Measurements 1 2 3 4 5

WHEEL CENTERLINE NEGATIVE CAMBER ANGLE PIVOT CENTERLINE SCRUB RADIUS TRUE VERTICAL

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

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

6 - KING PIN 7 - VERTICAL 8 - POSITIVE CASTER

To obtain an accurate alignment, a 4 wheel alignment machine must be used and the equipment calibration verified. NOTE: For an accurate wheel toe position adjustment the engine must be engine running. (1) Apply parking brakes. (2) Start the engine and turn wheels both ways before straightening the steering wheel. Center and secure the steering wheel. (3) Loosen the tie rod adjustment sleeve clamp bolts (Fig. 2). (4) Turn the sleeve to obtain the preferred positive TOE-IN specification. Position the clamp bolts as shown (Fig. 2) for proper clearance. (5) Tighten the clamp bolts to 68 NÂ·m (50 ft. lbs.).

WHEEL ALIGNMENT

2-5

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

SPECIFICATIONS ALIGNMENT NOTE: Specifications are in degrees.

FRONT WHEELS - STANDARD SUSPENSION SPECIFICATIONS DESCRIPTION

Fig. 2 Steering Linkage

SPECIFICATION

PREFERRED

CASTER + 6.75°

CAMBER 2 0.37°

TOTAL TOE-IN + 0.20°

RANGE

+ 6.0° to + 7.5°

2 0.75° to + 0.5°

+ .14° to + .26°

MAX RT/LT DIFFERENCE

0.5°

FRONT WHEELS - UP-COUNTRY SUSPENSION

1 - DRAG LINK ADJUSTMENT SLEEVE 2 - TIE ROD ADJUSTMENT SLEEVE

SPECIFICATIONS DESCRIPTION

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

SPECIFICATION

PREFERRED

CASTER + 6.5°

CAMBER 2 0.37°

TOTAL TOE-IN + 0.20°

RANGE

+ 5.7° to + 7.2°

2 0.75° to + 0°

+ 0.0° to + .36°

MAX RT/LT DIFFERENCE

0.5°

0.06°

REAR AXLE SPECIFICATIONS DESCRIPTION

SPECIFICATION

PREFERRED

CAMBER –.37°

THRUST ANGLE 0°

TOTAL TOE-IN +.37°

RANGE

0° to –.75°

± 0.25°

0° to +.70°

2-6

FRONT

FRONT TABLE OF CONTENTS page

page

FRONT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 STANDARD PROCEDURE - SERVICE WARNINGS AND CAUTIONS . . . . . . . . . . . . . . 6 SPECIFICATIONS TORQUE CHART ......................7 SPECIAL TOOLS FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . 8 BUSHINGS REMOVAL .............................9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 HUB / BEARING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REMOVAL .............................9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 KNUCKLE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL - STEERING KNUCKLE . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 LOWER BALL JOINT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 LOWER CONTROL ARM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11

SHOCK DESCRIPTION . . . . . OPERATION . . . . . . . REMOVAL . . . . . . . . . INSTALLATION . . . . . SPRING DESCRIPTION . . . . . OPERATION . . . . . . . REMOVAL . . . . . . . . . INSTALLATION . . . . . STABILIZER BAR DESCRIPTION . . . . . OPERATION . . . . . . . REMOVAL . . . . . . . . . INSTALLATION . . . . . TRACK BAR DESCRIPTION . . . . . OPERATION . . . . . . . REMOVAL . . . . . . . . . INSTALLATION . . . . . UPPER BALL JOINT REMOVAL . . . . . . . . . UPPER CONTROL ARM DESCRIPTION . . . . . OPERATION . . . . . . . REMOVAL . . . . . . . . . INSTALLATION . . . . .

FRONT

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

DESCRIPTION The front suspension (Fig. 1) is a link/coil design comprised of : • Drive axle • Shock absorbers • Coil springs • Upper and lower suspension arms • Stabilizer bar • Track bar • Jounce bumpers CAUTION: Components attached with a nut and cotter pin must be torqued to specification. Then if the slot in the nut does not line up with the cotter pin hole, tighten nut until it is aligned. Never loosen the nut to align the cotter pin hole.

. . . .

. 12 . 12 . 12 . 12

. . . .

. 12 . 13 . 13 . 13

. . . .

. 14 . 14 . 14 . 14

. . . .

. 14 . 14 . 14 . 14

. . . . . . . . . . . . . . . . . . . . 15 . . . .

. . . .

. 16 . 16 . 16 . 16

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

FRONT

WJ FRONT (Continued)

Fig. 1 Front 1 2 3 4 5 6

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

SPECIFICATIONS TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Shock Absorber Upper Nut

—

Shock Absorber Lower Nut

—

250

Suspension Arm Upper Axle Bracket Nut

—

Suspension Arm Upper Frame Bracket Bolt

—

Suspension Arm Lower Axle Bracket Nut

163

120

—

Suspension Arm Lower Frame Bracket Bolt

156

115

—

Stabilizer Bar Retainer Bolts

—

Stabilizer Bar Link Upper Nut

106

—

Stabilizer Bar Link Lower Nut

106

—

Track Bar Frame Bracket Nut

108

—

Track Bar Axle Bracket Bolt

100

—

Hub Bearing Knuckle Bolts

102

—

2-7

2-8

FRONT

FRONT (Continued)

SPECIAL TOOLS FRONT SUSPENSION

Remover C-4150A

Remover/Installer Suspension Bushing 7932

Remover/Installer 6289

Spacer 8279

Reciever 6761

Nut, Long 7603

Installer 6752

Bolt, Special 7604

FRONT

2-9

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

Fig. 3 Bushing Installation 1 2 3 4 5

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

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

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

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

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

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

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

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

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

2 - 10

FRONT

HUB / BEARING (Continued) ing (Fig. 4) from the steering knuckle and off the axle shaft.

installation of upper and lower ball studs require the use of Tool Kit 6289. (1) Remove hub bearing and axle shaft. (2) Disconnect the tie-rod or drag link from the steering knuckle arm,(Refer to 19 - STEERING/ LINKAGE/TIE ROD END - REMOVAL) . (3) Remove the cotter pins from the upper and lower ball studs. (4) Remove the upper and lower ball stud nuts. (5) Strike the steering knuckle with a brass hammer to loosen knuckle from the ball studs. Remove knuckle from ball studs (Fig. 5).

Fig. 4 Hub Bearing & Knuckle 1 - HUB BEARING 2 - KNUCKLE

INSTALLATION (1) Install the hub bearing to the knuckle. (2) Install the hub bearing to knuckle bolts and tighten to 102 N路m (75 ft. lbs.). (3) Install the hub washer and nut. Tighten the hub nut to 237 N路m (175 ft. lbs.). Install the nut retainer and a new cotter pin. (4) Install the brake rotor, caliper anchor, caliper and ABS wheel speed sensor,(Refer to 5 - BRAKES/ ELECTRICAL/FRONT WHEEL SPEED SENSOR INSTALLATION). (5) Install the wheel and tire assembly (Refer to 22 - TIRES/WHEELS - STANDARD PROCEDURE). (6) Remove the support and lower the vehicle.

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

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

REMOVAL - STEERING KNUCKLE Ball stud service procedures below require removal of the hub bearing and axle shaft. Removal and

Fig. 5 Steering Knuckle Removal/Installation 1 2 3 4

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

INSTALLATION (1) Position the steering knuckle on the ball studs. (2) Install and tighten the bottom retaining nut to 109 N路m (80 ft. lbs.) torque. Install new cotter pin. (3) Install and tighten the top retaining nut to 101 N路m (75 ft. lbs.) torque. Install new cotter pin. (4) Install the hub bearing and axle shaft. (5) Connect the tie-rod or drag link end to the steering knuckle arm.,(Refer to 19 - STEERING/ LINKAGE/TIE ROD END - INSTALLATION) .

FRONT

REMOVAL

LOWER BALL JOINT REMOVAL Ball stud service procedures below require removal of the hub bearing and axle shaft. Removal and installation of upper and lower ball studs require the use of Tool Kit 6289. (1) Position tools as shown to remove and install ball stud (Fig. 6).

(1) Raise the vehicle and support the front axle. (2) Remove the lower suspension arm nut and bolt from the axle bracket (Fig. 7). (3) Remove the nut and bolt from the frame rail bracket and remove the lower suspension arm (Fig. 7).

INSTALLATION (1) Position the lower suspension arm in the axle bracket and frame rail bracket.

LOWER CONTROL ARM

NOTE: The end of the arm with the oval bushing attaches to the axle bracket.

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

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

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

Fig. 6 Lower 1 2 3 4

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

2 - 11

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

2 - 12

FRONT

LOWER CONTROL ARM (Continued)

Fig. 8 Upper Shock Mounting

Fig. 7 Lower Suspension Arm 1 - LOWER SUSPENSION ARM 2 - FRAME RAIL BRACKET 3 - AXLE BRACKET

1 2 3 4

RETAINER STUD NUT GROMMET

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

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

REMOVAL (1) Remove the nut, retainer and grommet from the shock stud in the engine compartment (Fig. 8). (2) Raise and support the front axle. (3) Remove the lower mounting nuts from the axle bracket (Fig. 9). Remove the shock absorber.

Fig. 9 Lower Shock Mounting 1 - SHOCK ABSORBER 2 - MOUNTING NUTS

(5) Install the upper grommet, retainer and nut on the stud in the engine compartment. Hold the shock stud with a 8 mm wrench and tighten the nut to 35 N·m (26 ft. lbs.).

INSTALLATION (1) Position the lower retainer and grommet on the shock stud. Insert the shock absorber through the shock tower hole. (2) Install the lower shock studs into the axle bracket. (3) Install the mounting nuts and tighten to 28 N·m (250 in. lbs.). (4) Remove support and lower the vehicle.

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

FRONT

2 - 13

SPRING (Continued)

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

REMOVAL (1) Raise and support the vehicle. (2) Remove the wheel and tire assemblies. (3) Position a hydraulic jack under the axle to support it. (4) Remove shock absorbers lower mounting nuts from the axle brackets. (5) Remove the track bar mounting bolt from the axle bracket. NOTE: Make sure the lower part of the shock does not hold tension on the brake lines at the axle tube housing located at the lower shock mounting area. (6) Lower the axle until the spring is free from the upper mount and isolator (Fig. 10).

Fig. 11 Lower Isolator 1 2 3 4

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

CAUTION: Ensure the spring is positioned on the lower isolator with the end of the spring coil against the isolator spring locator (Fig. 12).

Fig. 10 Front Coil Spring 1 2 3 4

UPPER ISOLATOR COIL SPRING LOWER ISOLATOR STABILIZER LINK

Fig. 12 Isolator Spring Locator (7) Remove the spring from the vehicle. (8) Remove and inspect the upper and lower spring isolators.

INSTALLATION (1) Install the upper isolator. (2) Install the lower isolator with the isolator locator nub in the axle pad hole (Fig. 11). (3) Position the coil spring on the axle spring pad.

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

(4) Raise the axle and guide the springs onto the spring upper mounts and lower shock studs into the axle brackets. (5) Install the shock absorbers lower mounting nuts.

2 - 14

FRONT

SPRING (Continued) (6) Install the track bar to the axle bracket and install the mounting bolt. NOTE: It may be necessary to pry the axle assembly over to install the track bar bolt. (7) Remove the hydraulic jack from under the vehicle. (8) Tighten all suspension components to proper torque. (9) Install the wheel and tire assemblies. (10) Remove support and lower vehicle.

INSTALLATION (1) Position the stabilizer bar on the frame rail and install the retainers and bolts. Ensure the bar is centered with equal spacing on both sides. Tighten the bolts to 92 NÂˇm (68 ft. lbs.). (2) Install the links onto the stabilizer bar and axle brackets and install the bolts and nuts finger tight. (3) Remove the supports and lower the vehicle. (4) With the vehicle on the ground tighten the stabilizer bar link nuts to 106 NÂˇm (78 ft. lbs.).

STABILIZER BAR

TRACK BAR

DESCRIPTION

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

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

REMOVAL (1) Raise and support the vehicle. (2) Remove link nuts and bolts (Fig. 13) and remove the links. (3) Remove the stabilizer bar retainer bolts (Fig. 13)from the frame rails and remove the stabilizer bar.

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

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

REMOVAL (1) Raise and support the vehicle. (2) Remove the nut and bolt from the frame rail bracket (Fig. 14).

Fig. 14 Track Bar Frame Rail Bracket 1 - FRAME RAIL 2 - TRACK BAR

Fig. 13 Stabilizer Bar 1 2 3 4

LINK STABILIZER BAR BUSHING RETAINER

(3) Remove the bolt from the axle shaft tube bracket (Fig. 15). Remove the track bar.

INSTALLATION (1) Install the track bar to the axle tube bracket. Install the retaining bolt finger tight.

FRONT

2 - 15

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

UPPER BALL JOINT REMOVAL Fig. 15 Track Bar Axle Bracket 1 - AXLE BRACKET 2 - TRACK BAR

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

Ball stud service procedures below require removal of the hub bearing and axle shaft. Removal and installation of upper and lower ball studs require the use of Tool Kit 6289. (1) Position tools as shown to remove and install ball stud (Fig. 16).

Fig. 16 Upper

2 - 16

FRONT

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

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

REMOVAL (1) Raise vehicle and support the axle. (2) Remove the upper suspension arm mounting nut and bolt (Fig. 17) from the axle bracket.

Fig. 17 Upper Suspension Arm 1 - UPPER SUSPENSION ARM 2 - FRAME BOLT 3 - AXLE BOLT

(3) Remove the nut and bolt (Fig. 17) at the frame rail and remove the upper suspension arm.

INSTALLATION (1) Position the upper suspension arm at the axle and frame rail. (2) Install the bolts and finger tighten the nuts. (3) Remove the supports and lower the vehicle. (4) With the vehicle on the ground tighten the axle bracket nut and the frame bracket bolt to 61 NÂˇm (45 ft. lbs.). (5) Check the alignment if new parts were installed.

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