1997 jeep wrangler tj service repair manual

free service manual download

1. GROUPTABLOCATOR
ServiceManualCommentForms

(RearofManual)

2. TJ
INTRODUCTION
CONTENTS
GENERAL INFORMATIONII
VEHICLEIDENTIFICATIONNUMBR
TheVehicleIdentificationNuher(VIN)plateis
locatedonthelowerwindshieldenceneartheleft
A-pillar.TheVINcontains17charactersthatprovide
dataconcerningthevehicle.RefertotheVINdecod-
ingcharttodeterminetheidentificationofavehicle.
TheVehicleIdentificationNumberisalso
imprintedonthe:
"BodyCodePlate.
"VehicleSafetyCertificationLabel.
"Framerail.
VEHICLE~IDENTIFICATIONNUMBERDECODINGCHART
INTRODUCTION1
Toprotecttheconsumerfromtheftandpossible
fraudthemanufacturerisrequiredtoincludea
CheckDigitattheninthpositionoftheVehicleIden-
tificationNumber.Thecheckdigitisusedbythe
manufacturerandgovernmentagenciestoverifythe
authenticityofthevehicleandofficialdocumenta-
tion.Theformulatousethecheckdigitisnot
releasedtothegeneralpublic.
POSITION INTERPRETATION CODE=DESCRIPTION
1 reountryofOrigin 1=UnitedStates
2 Make J=Jeep
3 VehicleType 4=MPV
4 GrossVehicleWeightRating E=3001-4000lbs.
F=4001-5000lbs.
5 VehicleLine Y=Wrangler4X4
6 Series 1=Sport
2=SE
4=Sahara
7 BodyStyle 9=OpenBody
8 Engine
j
H=2.5LLeaded-Gasoline
P=2.5LUnleaded-Gasoline
S=4.OLUnleaded-Gasoline
V=4.OLLeaded-Gasoline
9 CheckDigit
10 ModelYear V=1997
11 ssemblyPlant P=Toledo#2
12thru17 VehicleBuildSequence
page page
GENERALINFORMATION METRICSYSTEM........................7
BODYCODEPLATE.........I.............2 TORQUEREFERENCES....................7
FASTENERIDENTIFICATION................4 VEHICLEDIMENSIONS....................3
FASTENERUSAGE.......................7 VEHICLEIDENTIFICATIONNUMBER.........1
INTERNATIONALVEHICLECONROLAND VEHICLESAFETYCERTIFICATIONLABEL.....2
DISPLAYSYMBOLS...................4

3. 2INTRODUCTION

TJ
GENERAL INFORMATION (Continued)
VEHICLESAFETYCERTIFICATIONLABEL
Avehiclesafetycertificationlabel(Fig.1)is
attachedtoeveryChryslerCorporationvehicle.The
labelcertifiesthatthevehicleconformstoallappli-
cableFederalMotorVehicleSafetyStandards.The
labelalsolists:
"PaintandTrimcodes.

Fig.2BodyCodePlateLocation
"Countryoforigin.
Thelabelislocatedonthedriver-sidedoorshut-

PRIMARY

SECONDARY

VINYLROOF
PAINT
PAINT
face.
MFDBY

CHRYSLER

DATEOFMFR

GUUR
CORPORATION

1X_XX

06400LB2903KG
GAURFRONT

uITHTIRES

RIMSAT

PSICOLD

VEHICLE

F

CAR
3300LB1497KG

P235/75R15X1_

15X6.5HD

35

ORDER
GAUpREAR

uITH11RES

RIMSAT

PSICOLD

NUMBER

LINE7SHELL
3850LB1747KG

P235/75R15XL

15X6.5HD

41

PAINT

(3)XXXX:XXXXKXXXXXXXXX

ENGINE
THISVEHICLECONFORMS10ALLAPPLICABLEFEDERALMOTORVEHICLESAFETY

PROCEDURE

(2)xxXXXXXXXXXXXXXXXX
STANDARDSINEFFECTONTHEDAZEOFMANUFACTURESHOUNABOVE,

(1)

XxXX

XXXXXXXXXXXXXXXXX

TRIM
VIN:XXXXXXXXXXXXXXXXX

TYPE:

TRUCK

SINGLEX

DUAL
BODYCODEPLATE
e020cdss
Fig.1VehicleSafetyCertificationLabel-Typical
O O
FLOOR
PAN
SNAP
BODY
CODE
PLATE
SNAP
FWD
TRANSMISSION VIN
MARKET
Fig.3BodyCodePlateDecoding
BODYCODEPLATE-LINE3
DIGITS1THROUGH12
LOCATIONANDDECODING

VehicleOrderNumber
Ametalbodycodeplateisattachedtothefloorpan
underthedriversseat(Fig.2).Disengagethesnaps

DIGITS13,14,AND15
attachingthecarpettothefloorpantoreadthe

OpenSpace
information.Therearesevenlinesofinformationon
thebodycodeplate.Lines4,5,6,and7arenotused

DIGITS16,17,AND18
todefineserviceinformation.Informationreadsfrom

CarLineShell
lefttoright,startingwithline3inthecenterofthe

"TJJ=Wrangler(LHD)
platetoline1atthebottomofthe

_plate(Fig.3).

"TJU-Wrangler(AHD)
Thelastcodeimprintedonavehiclecodeplatewill
befollowedbytheimprintedwordEND.Whentwo

DIGIT19
vehiclecodeplatesarerequired,,thelastavailable

PriceClass
spacesonthefirstplatewillbeimprintedwiththe

"L=Wrangler(All)
lettersCTD(forcontinued).
Whenasecondvehiclecodeplateisnecessary,the

DIGITS20AND21
firstfourspaceson'eachrowwillInotbeusedbecause

BodyType
oftheplateoverlap.

"77=WheelBase(93.4in.)
931N-S
"Monthandyearofvehiclemanufacture.
"GrossVehicleWeightRating(GVWR).Thegross
frontandrearaxleweightratings(GAWR's)are
basedonaminimumrimsizeandmaximumcoldtire
inflationpressure.
"VehicleIdentificationNumber(VIN). w.
"Typeofvehicle. .16
"Typeofrearwheels. FRONT
"Barcode. CARPET
"Month,DayandHour(MDH)offinalassembly.

4. TJ
GENERAL INFORMATION (0ontinued)
i
BODYCODEPLATE-LINE 2
DIGITS1,2,AND3
PaintProcedure
DIGIT4
OpenSpace
DIGITS5THROUGH8
PrimaryPaint
RefertoGroup23,Bodyforcolorcodes.
DIGIT9
OpenSpace
DIGITS10THROUGH13
SecondaryPaint
DIGIT14
OpenSpace
DIGITS15THROUGH18
InteriorTrimCode
DIGIT19
OpenSpace
DIGITS20,21,AND22
EngineCode
"EPE=2.5L4cyl.MPIGasoline
"ERH=4.OL6cyl.MPIGaso4ne
BODYCODEPLATELINE1
DIGITS1,2,AND3
TransmissionCodes
"DDQ=AX55-speedManual
"DDO=AX155-speedManual
"DGD=30RH3-speedAutomatic
DIGIT4
OpenSpace
DIGIT5
MarketCode
"B=International
"C=Canada
"M=Mexico
"U=UnitedStates
DIGIT6
OpenSpace
VEHICLEEXTERIORDIMENSIONS
VEHICLEINTERIORDIMENSIONS
INTRODUCTION 3
"DGG=32RH3-speedAutomatic
DIGITS7THROUGH23
VehicleIdentificationNumber(VIN)
RefertoVehicleIdentificationNumber(VIN)para-
graphforproperbreakdownofVINcode.
VEHICLEDIMENSIONS
Thevehicledimensiondatachartslisttheexterior
andinteriordimensions.Alldimensionsarelistedin
inchesandcentimeters.
HEAD HEAD
LEG SHOULDER HIP
FRONT/REAR FRONT/REAR
FRONT/REAR FRONT/REAR FRONT/REAR
SOFTTOP HAR~~TOP
42.3/40.2 40.9/391 41.0/36.4 51.9/57.3 51.1/43.5
107.5/102.2 103.8/909.4 104.1/92.4 131.9/145.5 129.7/110.5
MODEL WHEEL TRACK TRACK OVERALL
LENGTH HEIGHT
NAME BASE RONT REAR WIDTH
TJ-Wrangler 93.4 58.0147.3 58.0147.3 147.7375.1 66.7169.3 70.6179.4
237.3

5. 4INTRODUCTION
GENERALINFORMATION (Continued)
INTERNATIONAL CONTROLANDDISPLAY-SYMBOLS
INTERNATIONALVEHICLECONTROLANDDISPLAY
SYMBOLS
Thegraphicsymbolsillustratedinthefollowing
chartareusedtoidentifyvariousinstrumentcon-
trols.Thesymbolscorrespondtothecontrolsanddis-
playsthatarelocatedontheinstrumentpanel.
FASTENERIDENTIFICATION
THREADIDENTIFICATION
SAEandmetricbolt/nutthreadsarenotthesame.
ThedifferenceisdescribedintheThreadNotation
chart(Fig.4).
GRADE/CLASSIDENTIFICATION
TheSAEboltstrengthgradesrangefromgrade2
tograde8.Thehigherthegradenumber,thegreater
theboltstrength.Identificationisdeterminedbythe
linemarksonthetopofeachbolthead.Theactual
boltstrengthgradecorrespondstothenumberofline
TJ
Fig,4ThreadNotation-SAEandMetric
PR606B
marksplus2.Themostcommonlyusedmetricbolt
strengthclassesare9.8and12.9.Themetric
strengthclassidentificationnumberisimprintedon
theheadofthebolt.Thehighertheclassnumber,
thegreatertheboltstrength.Somemetricnutsare
imprintedwithasingle-digitstrengthclassonthe
nutface.RefertotheFastenerIdentificationand
FastenerStrengthCharts.
=D
1
_Q_
i
HEADLIGHTS,
PARKINGLIGHTS, WINDSHIELD
HIGHBEAM FOGLIGHTS PANELLIGHTS TURNSIGNAL HAZARDWARNING WASHER
13P
WINDSCREEN
WINDSHIELD WINDSHIELDWIPER DEMISTING REARWINDOW REARWINDOW
WIPER ANDWASHER ANDDEFROSTING VENTILATINGFAN DEFOGGER WIPER
.w.
LOW
REARWINDOW ENGINECOOLANT BATTERYCHARGING
WASHER FUEL TEMPERATURE CONDITION ENGINEOIL SEATBELT
REARHOOD
BRAKEFAILURE PARKINGBRAKE FRONTHOOD (TRUNK) HORN LIGHTER
J951N-23
INCH METRIC
5/16-18
M8X1.25
THREAD NUMBER THREAD DISTANCE
MAJOR OF MAJOR BETWEEN
DIAMETER THREADS DIAMETERINTHREADS IN
ININCHES PERINCH MILLIMETERS MILLIMETERS

6. TJ

INTRODUCTION 5
GENERALINFORMATION (~ontinued)
BoltHeadMarkings
BoltMarkingsandTorque-Metric
FASTENERIDENTIFICATION
CommercialSteelClass
8.8

10.9

12.9
l
~~
llhlll
~
8.s 10.9 12.9
Body
Size Torque Torque Torque
Diam. CastIron Aluminum CastIron Aluminum CastIron Aluminum
mm Nam ft-IbNam ft-lb Nam ft-IbNam ft-Ib Nam ft-IbNam ft-Ib
6 9 5 7 ',4 14 9 11 7 14 9 11 7
7 14 9 11 ',7 18 14 14 11 23 18 18 14
8 25 18 18 ll4 32 23 25 18 36 27 28 21
10 40 30 30 5 60 45 45 35 70 50 55 40
12 70 55 55 0 105 75 80 60 125 95 100 75
14 115 85 90 15 160 120 125 95 195 145 150110
16 180130 140 10 240 175 190 135 290 210 220165
18 230170 180 15 320 240 250 185 400 290 310230
BoltMarkingsandTorqueValues-U.S.Customary
SAEGradeNumber 5 8
BoltHeadMarkings
kaffii
TheseareallSAEGrade5(3)line i
Y
BoltTorque-Grade5Bolt BoltTorque-Grade8Bolt
BodySize CastIron'', Aluminum CastIron Aluminum
Nam #-I4 Nam ft-Ib Nam ft-Ib Nam ft-Ib
11,4-20 9 1 8 6 15 11 12 9
-28 12 0 9 7 18 13 14 10
5/16-18 20 16 12 30 22 24 18
-24 23 1
1,
19 14 33 24 25 19
3/8-16 40 3 25 20 55 40 40 30
-24 40 3 35 25 60 45 45 35
7/16-14 60 4 45 35 90 65 65 50
-20 65 5 55 40 95 70 75 55
1/2-13 95 70 75 55 130 95 100 75
-20 100 7 80 60 150 110 120 90
9/16-12 135 10 110 80 190 140 150 110
-18 150 11 115 85 210 155 170 125
5/8-11 180 13,1 150 110 255 190 205 150
-18 210 15 160 120 290 215 230 170
3/4-10 325 240 255 190 460 340 365 270
-16 365 270 285 210 515 380 410 300
7/8-9 490 360 380 280 745 550 600 440
-14 530 390 420 310 825 610 660 490
1-8 720 53(~ 570 420 1100 820 890 660
-14 800 590 650 480 1200 890 960 710

7. 6INTRODUCTION

TJ
GENERALINFORMATION (Continued)
HOWTODETERMINEBOLTSTRENGTH
FASTENERSTRENGTH
951N-4
Mark Class Mark Class
Hexagon 4- 4T Studbolt
headbolt 5- 5T
Bolt 6- 6T,
headheadNo.7- 7T Nomark
8- 8T
9- 9T ".~ 4T
10- 10T
11- 11T 01
O
Nomark 4T
Hexagon
flangebolt
O Nomark 4T Grooved
w/washer
hexagonbolt
p 6T
Hexagon
u
headbolt Two 5TO
protruding
U
lines
.Wr.
Hexagon
flangebolt Two
protruding 6T Weldedbolt
w/washer lines
hexagonbolt
Hexagon
headbolt Three
0
O
oprotruding 7T
a
'
lines 4T
Hexagon
headbolt Four
protruding 8T
0
o
lines

8. TJ
GENERAL INFORMATION (~ontinued)
FASTENERUSAGE
WARNING:USEOFANINCORECTFASTENER
MAYRESULTINCOMPONENT IMAGE ORPER-
SONALINJURY.
Figureart,specificationsandt
thisServiceManualareidentified
format.
Duringanymaintenanceorrep
importanttosalvageallfastener
forreassembly.Ifthefasteneris
fastenerofequivalentspecificatio~h
rquereferencesin
inmetricandSAE
itprocedures,itis
s(nuts,bolts,etc.)
notsalvageable,a
shouldbeused.
METRICSYSTEM
Themetricsystemisbasedo
ten,onehundred,onethousanda
5).
Thefollowingchartwillassistinconvertingmetric
unitstoequivalentEnglishandSAEunits,orvise
versa.
quantitiesofone,
donemillion(Fig.
Fig.5MetricPrefixes
CONVEOSION FORMULAS ANDEQUIVALENT VALUES
INTRODUCTION 7
Mega

-

(M)Million

Deci

-

(D)Tenth
Kilo

-

(K)Thousand

Centi-

(C)Hundreth
Milli

-

(m)Thousandth
J901N-2
RefertotheConversionCharttoconverttorque
valueslistedinmetricNewton-meters(N-m).Also,
usethecharttoconvertbetweenmillimeters(mm)
andinches(in.)
TORQUEREFERENCES
IndividualTorqueChartsappearattheendof
manyGroups.RefertotheStandardTorqueSpecifi-
cationsChartfortorquereferencesnotlistedinthe
individualtorquecharts.
J91IN-1
Multiply sly oGet Multiply By ToGet
in-Ibs x.11298 Newton-Meters(N"m) N-m x8.851 =In-Ibs
ft-Ibs x1.3558 Newton-Meters(N-m) N"m x0.7376 =ft-Ibs
InchesHg(60°F) x3.377 Kilopascals(kPa) kPo x0.2961 =InchesHg
psi x6.895 Kilopascals(kPa) kPa x0.145 =psi
Inches x25.4 bMillimeters(mm) mm x0.03937 Inches
Feet x0.3048 Meters(M) M x3.281 Feet
Yards x0.9144 Meters(M) M x1.0936 Yards
Miles x1.6093 Kilometers(Km) Km x0.6214 Miles
mph x1.6093 Kilometers/Hr.(Km/h) Km/h x0.6214 =mph
Feet/Sec. x0.3048 Meters/Sec.(M/S) M/S x3.281 =Feet/Sec.
Kilometers/Hr. x0.27778 Meters/Sec.(M/S) WS x3.600 =Kilometers/Hr.
mph x0.4470 Meters/Sec.(M/S) WS x2.237 -mph
COMMON METRICEQUIVALENTS
1Inch-25Millimeters 1CubicInch =16CubicCentimeters
1Foot=0.3Meter 1CubicFoot =0.03CubicMeter
1Yard=0.9Meter
1CubicYard =0.8CubicMeter
1Mile=1.6Kilometers

9. 8INTRODUCTION

TJ
GENERALINFORMATION (Continued)
METRICCONVERSION
in-IbstoN"m

Nemtoin-Ibs
ft-IbstoNem

Nemtoft-Ibs
in.tomm

mmtoin.
J901N-10
in-lbNamin-IbNamin-IbNamin-IbNamin-IbNam
Nam
in-IbNam in-IbNam in-IbNam in-IbNam in-Ib
2 .226042 4.745382 9.264612213.783916218.3032
.2 1.77024.237.17478.272.579212.2107.983716.2143.3882
4 .451944 4.971384 9.490612414.009916418.5292
.43.54044.438.94498.474.349412.4109.753916.4145.1584
6 .677946 5.197286 9.716512614.235916618.7552
.65.31074.640.71528.676.119712.6111.524216.6146.9287
8 .903948 5.423288 9.942512814.461816818.9811
.87.08094.842.48548.877.889912.8113.294416.8148.6989
10 1.129850 5.649290 10.168513014.687817019.20711 8.85115 44.25569 79.660113 115.064617150.4691
12 1.355852 5.875192 10.394413214.913817219.4331
1.210.62135.246.02589.281.430313.2116.834817.2152.2393
14 1.581854 6.101194 10.620413415.139717419.6590
1-412.39165.447.79619.483.200613.4118.605117.4154.0096
16 1.807756 6.327096 10.846413615.365717619.88501.614.16185.649.56639.684.970813.6120.375317.6155.7798
18 2.033758 6.553098 11.072313815.591717820.1110
1.815.93205.851.33659.886.741013.8122.145517.8157.5500
20 2.259760 6.779010011.298314015.817618020.33692
17.70226 53.106710 88.511214 123.915718159.3202
22 2.485662 7.0049'10211.524314216.043618220.56292.219.47256.254.877010.290.281514.2125.686018.5163.7458
24 2.711664 7.230910411.750214416.269618420.7889
2.421.24276.456.647210.492.051714.4127.456219168.1714
26 2.937666 7.456910611.976214616.495518621.0148
2-623.01296.658.417410.693.821914.6129.226419.5172.5970
28 3.163568 7.682810812.202214816.721518821.2408
2.824.78316.860.187610.895.592114.8130.996620177.0225
30 3.389570 7.908811012.428115016.947519021.46683 26.55347 61.957911 97.362415 132.766920.5181.4480
32 3.615572 8.134811212.654115217.173419221.6927
3.228.32367.263.728111.299.132615.2134.537121185.8736
34 3.841474 8.360711412.880115417.399419421.9187
3.430.09387.465.498311.4100.902815.4136.307322194.7247
36 4.067476 8.586711613.106015617.625319622.1447
3.631.86407.667.268511.6102.673015.6138.077523203.5759
38 4.293478 8.812711813.332015817.851319822.3706
3.833.63427.869.038811.8104.443315.8139.847824212.4270
40 4.519380 9.038612013.558016018.077320022.59664 3540458 70.809012 106.213516 141.618025221.2781
ft-IbNamft-IbNam ft-IbNam ft-IbNamft-IbNam Nam ft-IbNam ft-IbNam ft-IbNam ft-IbNam ft-Ib
1 1.35582128.47224155.588561 82.704981109.82121 .73762115.98884130.24006144.99138159.7425
2 2.71162229.82804256.944462 84.060782111.17702 1.47512216.22644230.97766245.72898260.4801
3 4.06752331.18384358.30026~3~85.416583112.53283 2.212723 16.96394331.71526346.46648361.2177
4 5.42332432.53964459.656064 86.772384113.88884 2.950224 17.70154432.45276447.20408461.9552
5 6.77912533.89544561.011865 88.128185115.24465 3.687825 18.43914533.19036547.94158562.6928
6 8.13492635.25134662.367666 89.484086116.60046 4.425426 19.17664633.92796648.67918663.4303
7 9.49072736.60714763.723467 90.839887117.95627 5.162927 19.91424734.66546749.41678764.1679
810.84652837.96294865.0793168 92.195688119.31208 5.90052820.65174835.40306850.15428864.9545
912.20242939.31874966.435169 93.551489120.66789 6.63812921.38934936.14056950.89188965.6430
1013.55823040.67455067.790970 94.907390122.023610 7.37563022.12695036.87817051.62939066.3806
1114.91403142.03045169.146771 96.263191123.379411 8.11323122.86445137.61577152.36699167.1181
1216.26983243.38625270.502572 97.618992124.735212 8.85073223.60205238.35327253.10459267.8557
1317.62563344.74205371.858373 98.974793126.0910.13 9.58833324.33955339.09087353.84209368.5933
1418.98153446.09785473.214274100.331694127.44681410.32593425.07715439.82847454.57209469.3308
1520.33733547.45365574.570075101.686295128.80261511.06343525.81475540.56597555.31729570.0684
1621.69313648.80945675.925876103.042296130.15861611.80103626.55225641.30357656.05479670.8060
1723.04893750.16535777.281677104.398097131.51441712.53863727.28985742.04107756.79239771.5435
1824.40473851.52115878.637478105.753898132.87021813.27613828.02745842.77867857.52989872.2611
1925.76053952.87695979.993379107.119699134.22601914.01373928.76495943.51627958.26749973.0187
2027.11644054.23276081.349180108.4654100135.582020 14.75124029.50256044.25378059.005010073.7562
in. mm in. mm in. mm in. mm in. mm mm in.mm in.
mm in.mm in.mm in.
.01 254.21 5.334.4110.414.6115.494.8120.574.01.00039.21.00827.41.01614.61.02402.81.03189
.02 .508.22 5.588.4210.668.6215.748.8220.828.02.00079.22.00866.42.01654.62.02441.82.03228
.03 .762.23 5.842.4310.922.6316.002.8321.082.03.00118.23.00906.43.01693.63.02480.83.03268
.04 1.01624 6.096.4411.176.6416.256.8421.33604 00157.24.00945.44.01732.64.02520.84.03307
.05 1.27025 6.350.4511.430.6516.510.8521.590.05.00197.25.00984.45.01772.65.02559.85.03346
.06 1.524.26 6.604.4611.684.6616.764.8621.844.06.0023626 01024.46.0181166 .02598.86.03386
.07 1.778.27 6.858.4711.938.6717.018.8722.098.07.00276.27.01063.47.01850.67.02638.87.03425
08 2.032.28 7.112.4812.192.6817.272.8822.352.0800315.28.01102.48.01890.68.02677.88.03465
.092.286.29 7.366.4912.446.6917.526.8922.606.09.00354.29.01142.49.01929.69.02717.89.03504
.102.540.30 7.620.5012.700.'7017.780.9022.86010.00394.30 01181.50 01969.70 02756.90.03543
11 2.794.31 7.874.5112.954.7118.034.9123.114.11.00433.31.01220.51.02008.71.02795.91.03583
12 3.04832 8.128.5213.208.7218.288.9223.36812 00472.32.01260.52.02047.72.02835.92.03622
13 3.302.33 8.382.5313.462.7318.542.9323.622.13.00512.33.01299.53.02087.73.02874.93.03661
14 3.556.34 8.636.5413.716.7418.796.9423.876.14.0055134 01339.54.02126.74 02913.94.03701
15 3.810.35 8.890.5513.970.7519.0509524.130.15.00591.35.01378.55.02165.75.02953.9503740
16 4.06436 9.1445614.224.7619.304.9624.38416.00630.36.01417.56.02205.76.02992.96.03780
17 3.31837 9.3985714.478.7719.558.9724.638.17.00669.37.01457.57.02244.77 03032.97.03819
18 4.57238 9.6525814.732.7819.8129824.89218.00709.38 01496.58 02283.78 03071.98.03858
19 4.826.39 9.906.5914.986.7920.0669925.146.1900748.39.01535.59.02323.79.03110.9903898
20 5.08040 10.1606015.240.8020.3201.0025.40020 00787.40.01575.60.02362.80 031501.00.03937

10. TJ

-- INTRODUCTION 9
GENERAL INFORMATION (IIontinued)
TORQUESPECIFICATIONS
SPECIFIEDTORQUEFORSTANDARDBOLTS
Specifitorque
ClassDiameterPitchi Hexagonheadbolt Hexagonflangebolt
mm mm ,, kgf-cm ft-Ibf Nom kgf-cm ft-Ibf
6 1 5 55 48in.-Ibf 6 60 52in.-16f
8 1.25 12.5 130 9 14 145 10
4T 10 1.25 126 260 19 29 290 21
12 1.25 47 480 35 53 540 39
14 1.5 74 760 55 84 850 61
16 1.5 11,15 1,150 83 - - -
6 1 6.5 65 56in.-I6F 7.5 75 65in.-I6f
8 1.25 15.5 160 12 17.5 175 13
5T 10 1.25 32 330 24 36 360 26
12 1.25 59 600 43 65 670 48
14 1.5 91 930 67 100 1,050 76
16 1.5 11,40 1,400 101 - - -
6 1 8 80 69in.-I6F 9 90 78in.-I6f
8 1.25 '19 195 14 21 210 15
6T 10 1.25 39 400 29 44 440 32
12 1.25 71 730 53 80 810 59
14 1.5 1:10 1,100 80 125 1,250 90
16 1.5 170 1,750 127 - - -
6 1 10.5 110 8 12 120 9
8 1.25 25 260 19 28 290 21
7T 10 1.25 'I52 530 38 58 590 43
12 1.25 95 970 70 105 1,050 76
14 1.5 1145 1,500 108 165 1,700 123
16 1.5 230 2,300 166 - - -
8 1.25 29 300 22 33 330 24
8T 10 1.25 61 620 45 68 690 50
12 1.251'10 1,100 80 120 1,250 90
8 1.25 34 340 25 37 380 27
9T 10 1.25 70 710 51 78 790 57
12 1.251:125 1,300 94 140 1,450 105
8 1.25 38 390 28 42 430 31
10T 10 1.25 78 800 58 88 890 64
12 1.25140 1,450 105 155 1,600 116
8 1.25 42 430 31 47 480 35
11T 10 1.25 87 890 64 97 990 72
12 1.25155 1,600 116 175 1,800 130

11. TJ

'~

LUBRICATIONANDMAINTENANCE

0-1
LUBRICATIONANDMAINTENANCE
CONTENTS
page
GENERALINFORMATION

....
.
'.......
.
.....1

MAINTENANCESCHEDULES

................3
JUMPSTARTING,HOISTINGANbTOWING....8
GENERALINFORMATION
CLASSIFICATIONOFLUBRICANTS...........2
FLUIDCAPACITIES.......................2
INTERNATIONALSYMBOLS

..j..............1
GENERAL INFORMATION
page
INTRODUCTION
Serviceandmaintenanceproceduresforcompo-
nentsandsystemslistedinSchedule-AorBcanbe
foundbyusingtheGroupTabLocatorindexatthe
frontofthismanual.Ifitisnotclearwhichgroup
containstheinformationneeded,'refertotheindexat
i
thebackofthismanual.
Therearetwomaintenanceschedulesthatshow
properservicebasedontheconditionsthatthevehi-
cleissubjectedto.
Schedule-A,listsscheduledImaintenancetobe
performedwhenthevehicleisusedforgeneraltrans-
portation.
Schedule-B,listsmaintenanceintervalsforvehi-
clesthatareoperatedundertheconditionslistedat
thebeginningoftheMaintenanceSchedulesection.
Usetheschedule'thatbestdescribesyourdriving
conditions.
Wheretimeandmileagearelisted,followthe
intervalthatoccursfirst.
PARTSANDLUBRICANTRECOMMENDATIONS
Whenserviceisrequired,ChryslerCorporation
recommendsthatonlyMopar8brandparts,lubri-
cantsandchemicalsbeused.Moparprovidesthe
bestengineeredproductsforservicingChryslerCor-
porationvehicles.
GENERAL INFORMATION
INDEX
Fig.1InternationalSymbols
page
page
INTRODUCTION.........................1
PARTSANDLUBRICANTRECOMMENDATIONS
........................................1
INTERNATIONALSYMBOLS
ChryslerCorporationusesinternationalsymbolsto
identifyenginecompartmentlubricantandfluid
inspectionandfilllocations(Fig.1).
CHRYSLER CORPORATION
0
ENGINEOIL
AUTOMATIC
TRANSMISSION
FLUID
ENGINE
COOLANT
BRAKEFLUID
POWER
STEERING
FLUID
WINDSHIELD
WASHERFLUID
9500-1

12. 0-2

LUBRICATIONANDMAINTENANCE
GENERAL INFORMATION (Continued)
CLASSIFICATIONOFLUBRICANTS
Onlylubricantsthatareendorsedbythefollowing
organizationshouldbeusedtoserviceaChrysler
Corporationvehicle.
"SocietyofAutomotiveEngineers(SAE)
"AmericanPetroleumInstitute(API)(Fig.2)
"NationalLubricatingGreaseInstitute(NLGI)
(Fig.3)
ENGINEOIL
-'svLSROLE
udJ
:'
cFR-Eo
Tn
Fig.2APISymbol
9400-9
SAEGRADERATINGINDICATESENGINEOILVISCOSITY
AnSAEviscositygradeisusedtospecifytheviscosity
ofengineoil.SAE30specifiesasingleviscosityengine
oil.Engineoilsalsohavemultipleviscosities.Theseare
specifiedwithadualSAEviscositygradewhichindi-
catesthecold-to-hottemperatureviscosityrange.
"SAE30=singlegradeengineoil.
"SAEIOW-30=multiplegradeengineoil.
APIQUALITYCLASSIFICATION
TheAPIServiceGradespecifiesthetypeofperfor-
mancetheengineoilisintendedtoprovide.TheAPI
ServiceGradespecificationsalsoapplytoenergycon-
servingengine,oils.
UseengineoilthatisAPIServiceGradeCertified
oranoilthatconformstotheAPIServiceGradeSH
orSH/CD.MOPARengineoilsconformtoallofthese
servicegrades.
RefertoGroup9,Engineforengineoilspecification.
GEARLUBRICANTS
SAEratingsalsoapplytomultiplegradegear
lubricants.Inaddition,APIclassificationdefinesthe
lubricantsusage.
LUBRICANTSANDGREASES
Lubricatinggreaseisratedforqualityandusage
bytheNLGI.AllapprovedproductshavetheNLGI
symbol(Fig.3)onthelabel.AtthebottomNLGI
symbolistheusageandqualityidentificationletters.
Wheelbearinglubricantisidentifiedbytheletter
"G".Chassislubricant,isidentifiedIbythelatter"L".
Theletterfollowingtheusageletterindicatesthe
NATIONAL LUBRICATING
GREASEINSTITUTE
NLGI
AUTOMOTIVE
WHEELBEARING8CHASSIS
LUBRICANT
GC
Fig.3NLGISymbol
FLUIDCAPACITIES
FUELTANK
ENGINEOIL
COOLINGSYSTEM
AUTOMATIC TRANSMISSION
Dryfillcapacity*
MANUALTRANSMISSION
TRANSFERCASE
FRONTAXLE
REARAXLE
NATIONALLUBRICATING
GREASE
INSTITUTE
NLGI
AUTOMOTIVE
WHEELBEARING8CHASSIS
LUBRICANT
LB
9200-7
TJ
qualityofthelubricant.Thefollowingsymbolsindi-
catethehighestquality.
NATIONAL LUBRICATING
GREASEINSTITUTE
NLGI
AUTOMOTIVE
WHEELBEARING8CHASSIS
LUBRICANT
GC-LB
WHEEL

CHASSIS

CHASSISAND
BEARINGS

LUBRICATION

WHEELBEARINGS
Standard.......................56.8L(15gal.)
Optional......................71.9L(19.0gal.)
2.5L...........................3.8L(4.0qts.)
4.OL...........................5.7L(6.0qts.)
2.5L...........................8.5L(9.0qts.)
4.OL..........................9.9L(10.5qts.)
32RH

.........................8.1L(17.lpts.)
30RH.........................6.6L(14.0pts.)
*Dependingontypeandsizeofinternalcooler,
lengthandinsidediameterofcoolerlines,oruseof
anauxiliarycooler,thesefiguresmayvary.Referto
Group21,Transmissionforproperfluidfillprocedure.
AX5...........................3.2L(3.3qts.)
AX15........................3.15L(3.32qts.)
COMMAND-TRAC 231(AutoTrans)..1.0L(2.2pts.)
COMMAND-TRAC 231(ManTrans).1.5L(3.25pts.)
MODEL181...................1.65L(3.76pts.)
MODEL216...................1.77L(3.75pts.)
MODEL194....................1.6L(3.5pts.*)
*WhenequippedwithTRAC-LOK,include2
ouncesofFrictionModifierAdditive.

13. TJ
GENERALINFORMATION
INTRODUCTION .......................3
SCHEDULE-A ...........
I'~
.............3
GENERAL INFORMATION
INTRODUCTION
TherearetwomaintenancesIhedulesthatshow
properserviceintervalsforTJI!vehicles.Usethe
schedulethatbestdescribestheconditionsthevehi-
cleisoperatedunder.Whenm~leageandtimeis
listed,followtheintervalthatoccursfirst.
Schedule-Alistsallthescheduledmaintenanceto
beperformedundernormaloperatingconditions.
highspeedsduringhotweather,above90°F(32°C)
"Offroaddriving
"Desertoperation
EMISSIONCONTROLSYSTEMMAINTENANCE
Thescheduledemissionmaintenancelistedinbold
typeontheMaintenanceSchedules,mustbedoneat
themileagespecifiedtoassurethecontinuedproper
functioningoftheemissioncontrolsystem.These,
andallothermaintenanceservicesincludedinthis
manual,shouldbedonetoprovidethebestvehicle
performanceandreliability.Modefrequentmainte-
nancemaybeneededforvehiclesIinsevereoperating
conditionssuchasdustyareasandveryshorttrip
driving.
UNSCHEDULED INSPECTION
AtEachStopForFuel
"Checkengineoillevel,addasrequired.
"Checkwindshieldwashersolventandaddif
required.
OnceAMonth
"Checktirepressureandlookforunusualwear
ordamage.
AINTENANCE SCHEDULES
INDEX
page
LUBRICATIONANDMAINTENANCE

0-3
page
SCHEDULE-13 ..........................4
UNSCHEDULED INSPECTION...............3
"Inspectbatteryandcleanandtightenterminals
asrequired.Checkelectrolytelevelandaddwateras
needed.
"Checkfluidlevelsofcoolantreservoir,power
steering,brakemastercylinder,andtransmission
andaddasneeded.
"Checkalllightsandallotherelectricalitemsfor
correctoperation.
AtEachOilChange
"Aftercompletionofoff-road(4WD)operation,the
undersideofthevehicleshouldbethoroughly
inspected.Examinethreadedfastenersforlooseness.
SCHEDULE-A
7,500Miles(12000km)orat6months
"Changeengineoil.
"Replaceengineoilfilter.
"Lubricatesteeringlinkage.
15,000Miles(24000km)orat12months
"Changeengineoil.
"Replaceengineoilfilter.
"Lubricatesteeringlinkage.
22,500Miles(36000km)orat18months
"Changeengineoil.
"Replaceengineoilfilter.
"Lubricatesteeringlinkage.
"Inspectbrakelinings.
30,000Miles(48000km)orat24months
"Changeengineoil.
"Replaceengineoilfilter.
"Replaceengineaircleanerelement.
Schedule-B isascheduleforvehiclesthatare
usuallyoperatedunderoneormoreofthefollowing
conditions:
"FrequentshorttripsdrivingIessthan5miles(8
"Inspectexhaustsystem.
"Inspectbrakehoses.
"Rotatethetiresateachoilchangeinterval
shownonSchedule-A (7,500miles)oreveryother
km)
intervalshownonSchedule-13(6,000miles).
"Frequentdrivingindustyconditions
"Checkcoolantlevel,hoses,andclamps.
"Frequenttrailertowing
"Lubricatepropellershaftuniversaljointsand
"Extensiveidling
slipsplines(ifequipped).
"Morethan50%ofyourdrivingisatsustained "Lubricatesuspensionballjoints.

14. 0-4

LUBRICATIONANDMAINTENANCE
GENERALINFORMATION (Continued)
37,500Miles(60000km)orat30months
"Changeengineoil.
"Replaceengineoilfilter.
"Lubricatesteeringlinkage.
"Drainandrefillmanualtransmissionfluid.
45,000Miles(72000km)orat36months
"Changeengineoil.
"Replaceengineoilfilter.
"Lubricatesteeringlinkage.
"Inspectbrakelinings.
"Flushandreplaceenginecoolantat36months,
regardlessofmileage.
52,500Miles(84000km)orat42months
"Flushandreplaceenginecoolantifnotdoneat
36months.
60,000Miles(96000km)orat48months
"Changeengineoil.
"Replaceengineoilfilter.
"Replaceengineaircleanerelement.
"Replaceignitioncables.
"Replacesparkplugs.
"Inspectdrivebelts.Adjustasneeded.
"Lubricatesteeringlinkage.
"Drainandrefillautomatictransmissionfluid.
"Drainandrefilltransfercasefluid.
67,500Miles(108000km)orat54months
"Changeengineoil.
"Replaceengineoilfilter.
"Lubricatesteeringlinkage.
"Inspectbrakelinings.
75,000Miles(120000km)orat60months
"Changeengineoil.
"Replaceengineoilfilter.
"Lubricatesteeringlinkage.
"Drainandrefillmanualtransmissionfluid.
"Flushandreplaceenginecoolantifithasbeen
30,000miles(48000km)or24'monthssincelast
change.
82,500Miles(132000km)orat6
"Changeengineoil.
"Replaceengineoilfilter.
"Lubricatesteeringlinkage.
months
TJ
"Changeengineoil.
"Replaceengineoilfilter.
"Replaceengineaircleanerelement.
"Replacesparkplugs.
"Inspectdrivebelts.Adjustasneeded.
"Lubricatesteeringlinkage.
"Drainandrefillautomatictransmissionfluid.
"Drainandrefilltransfercasefluid.
"Inspectbrakelinings.
97,500Miles(156000km)orat78months
"Changeengineoil.
"Replaceengineoilfilter.
"Lubricatesteeringlinkage.
105,000Miles(168000km)orat84months
30,000miles(48000km)or24monthssincelast
change.
112,500Miles(180000km)orat90months
"Changeengineoil.
"Replaceengineoilfilter.
"Lubricatesteeringlinkage.
"Drainandrefillmanualtransmissionfluid.
"Inspectbrakelinings.
"Flushandreplaceenginecoolantifithasbeen
30,000miles(48000km)or24monthssincelast
change.
120,000Miles(192000km)orat96months
"Changeengineoil.
"Replaceengineoilfilter.
"Replaceengineaircleanerelement.
"Replaceignitioncables.
"Replacesparkplugs.
"Inspectdrivebelts.Adjustasneeded.
"Lubricatesteeringlinkage.
"Drainandrefillautomatictransmissionfluid.
"Drainandrefilltransfercasefluid.
Inspectionandserviceshouldalsobeperformed
anytimeamalfunctionisobservedorsuspected.
SCHEDULE-B
3,000Miles(4800km)
"Changeengineoil.
"Replaceengineoilfilter.
"Changeengineoil. "Changeengineoil.
"Replaceengineoilfilter. "Replaceengineoilfilter.
"Lubricatesteeringlinkage. "Lubricatesteeringlinkage.
"Flushandreplaceenginecoolantifithasbeen
"Replacesparkplugs. "Flushandreplaceenginecoolantifithasbeen
"Inspectdrivebelts.Adjustasneeded. 30,000miles(48000km)or24monthssincelast
"Lubricatesteeringlinkage. change.
"Drainandrefillautomatictransmissionfluid.
"Drainandrefilltransfercasefluid.
90,000Miles(144000km)orat72months

15. 12,000Miles(19200km)
15,000Miles(24000km)
"Changeengineoil.
"Replaceengineoilfilter.
"Inspectengineaircleanerelement,replace
asnecessary.
18,000miles(29000km)
"Changeengineoil.
"Replaceengineoilfilter.

i
"Lubricatesteeringlinkage.
"Drainandrefillmanualtransmissionfluid.
21,000Miles(34000km)
"Changeengineoil.
"Replaceengineoilfilter.
27,000Miles(43000km)
"Changeengineoil.
"Replaceengineoilfilter.
30,000Miles48000km)
24,000Miles(38000km)
"Changeengineoil.
"Replaceengineoilfilter.
"Lubricatesteeringlinkage.
"Drainandrefillautomatictransmissionfluid.
"Drainandrefillfrontandrearaxles.*
"Inspectbrakelinings.
"Changeengineoil.
"Replaceengineaircleanerelement.
"Replacesparkplugs.
"Inspectdrivebelts.Adjustasneeded.
"Lubricatesteeringlinkage.
"Drainandrefilltransfercastefluid.
Replaceengineoilfilter.
33,000Miles(53000km)
"Changeengineoil.
"Replaceengineoilfilter.
5
39,000Miles(62000km)
45,000Miles(72000km)
"Changeengineoil.
"Replaceengineoilfilter.
"Inspectengineaircleanerelement,replace
asnecessary.
48,000Miles(77000km)
"Changeengineoil.
"Replaceengineoilfilter.
"Lubricatesteeringlinkage.
"Drainandrefillautomatictransmissionfluid.
"Drainandrefillfrontandrearaxles.*
"Inspectbrakelinings.
51,000Miles(82000km)
"Changeengineoil.
"Replaceengineoilfilter.
"Flushandreplaceenginecoolant.
54,000miles(86400km)
"Changeengineoil.
"Replaceengineoilfilter.
"Lubricatesteeringlinkage.
"Drainandrefillmanualtransmissionfluid.
57,000Miles(91000km)
"Changeengineoil.
"Replaceengineoilfilter.
60,000Miles(96000km)
"Changeengineoil.
"Replaceengineoilfilter.
"Replaceengineaircleanerelement.
"Replaceignitioncables.
"Replacesparkplugs.
"Inspectdrivebelts.Adjustasneeded.
"Lubricatesteeringlinkage.
"Drainandrefillautomatictransmissionfluid.
"Drainandrefilltransfercasefluid.
TJ
GENERALINFORMATION (Continued)
6,000Miles(9600km)
LUBRICATIONANDMAINTENANCE 0-
36,000Miles(58000km)
"Changeengineoil. "Changeengineoil.
"Replaceengineoilfilter. "Replaceengineoilfilter.
"Lubricatesteeringlinkage. "Lubricatesteeringlinkage.
"Drainandrefillmanualtransmissionfluid.
9,000Miles(14400km) "Drainandrefillautomatictransmissionfluid.
"Changeengineoil. "Drainandrefillfrontandrearaxles.*
"Replaceengineoilfilter. "Inspectbrakelinings.
"Changeengineoil. "Changeengineoil.
"Replaceengineoilfilter. "Replaceengineoilfilter.
"Lubricatesteeringlinkage.
"Drainandrefillautomatictransmissionfluid. 42,000Miles(67000km)
"Drainandrefillfrontandrearaxles.* "Changeengineoil.
"Inspectbrakelinings. "Replaceengineoilfilter.
"Lubricatesteeringlinkage.

16. "Inspectbrakelinings.
75,000Miles(120000km)
"Changeengineoil.
"Replaceengineoilfilter.
"Inspectengineairfilter,replaceasneces-
sary.
78,000Miles(125000km)
"Changeengineoil.
"Replaceengineoilfilter.
"Lubricatesteeringlinkage.
81,000Miles(130000km)
"Changeengineoil.
"Replaceengineoilfilter.
"Flushandreplaceenginecoolant.
84,000Miles(134400km)
90,000Miles(144000km)
"Changeengineoil.
"Replaceengineoilfilter.
"Replaceengineaircleanerelement.
"Changeengineoil.
"Replaceengineoilfilter.
"Lubricatesteeringlinkage.
TJ
105,000Miles(168000km)
"Changeengineoil.
"Replaceengineoilfilter.
"Inspectengineaircleanerelement,replace
asnecessary.
108,000Miles(172800km)
"Changeengineoil.
"Replaceengineoilfilter.
"Lubricatesteeringlinkage.
"Drainandrefillmanualtransmissionfluid.
"Drainandrefillautomatictransmissionfluid.
"Drainandrefillfrontandrearaxles.*
"Inspectbrakelinings.
117,000Miles(187200km)
"Changeengineoil.
"Replaceengineoilfilter.
66,000miles(105600km)
"Changeengineoil.
"Replaceengineoilfilter.
"Lubricatesteeringlinkage.
93,000Miles(149000km)
"Changeengineoil.
"Replaceengineoilfilter.
96,000Miles(154000km)
"Changeengineoil.
69,000Miles(110000km) "Replaceengineoilfilter.
"Changeengineoil. "Lubricatesteeringlinkage.
"Replaceengineoilfilter. "Drainandrefillautomatictransmissionfluid.
"Drainandrefillfrontandrearaxles.*
72,000Miles(115200km) "Inspectbrakelinings.
"Changeengineoil.
"Replaceengineoilfilter. 99,000Miles(158000km)
"Lubricatesteeringlinkage. "Changeengineoil.
"Drainandrefillmanualtransmissionfluid. "Replaceengineoilfilter.
"Drainandrefillautomatictransmissionfluid.
"Drainandrefillfrontandrearaxles.* 102,000Miles(163000km)
"Changeengineoil. 111,000Miles(177600km)
"Replaceengineoilfilter. "Changeengineoil.
"Lubricatesteeringlinkage. "Replaceengineoilfiber.
"Drainandrefillautomatictransmissionfluid. "Flushandreplaceenginecoolant.
"Drainandrefillfrontandrearaxles.*
"Inspectbrakelinings. 114,000Miles(182400km)
0-6LUBRICATIONANDMAINTENANCE
GENERAL INFORMATION (Continued)
"Drainandrefillfrontandrearaxles.* "Replacesparkplugs.
"Inspectbrakelinings. "Inspectdrivebelts.Adjustasneeded.
"Lubricatesteeringlinkage.
63,000Miles(102000km) "Drainandrefillmanualtransmissionfluid.
"Changeengineoil. "Drainandrefilltransfercasefluid.
"Replaceengineoilfilter.
"Changeengineoil.
87,000Miles(140000km) "Replaceengineoilfilter.
"Changeengineoil. "Lubricatesteeringlinkage.
"Replaceengineoilfilter.

17. TJ
GENERALINFORMATION ~I(Continued)
LUBRICATIONANDMAINTENANCE

0-7
120,000Miles(192000km)

!

"Drainandrefillfrontandrearaxles.*
"Changeengineoil.

"Inspectbrakelinings.
"Replaceengineoilfilter.

*Off-highwayoperation,trailertowing,taxi,limou-
"Replaceengineaircleanerelement.

sine,bus,snowplowing,orothertypesofcommercial
"Replaceignitioncables.

serviceorprolongedoperationwithheavyloading,
"Replacesparkplugs.

especiallyinhotweather,requirefrontandrearaxle
"Inspectdrivebelts.Adjustasneeded.

serviceindicatedwitha*inSchedule-B.Perform
"Lubricatesteeringlinkage.
I

theseservicesifthevehicleisoperatedunderthese
"Drainandrefillautomatictransmissionfluid.

conditions.
"Drainandrefilltransfercasefluid.

18. 0-8

LUBRICATIONANDMAINTENANCE
SERVICEPROCEDURES
JUMPSTARTINGPROCEDURE
JUMPSTARTING,HOISTINGANDTOWING
WARNING:REVIEWALLSAFETYPRECAUTIONS
ANDWARNINGS INGROUP8A,BATTERY/START-
ING/CHARGINGSYSTEMSDIAGNOSTICS.
DONOTJUMPSTARTAFROZENBATTERY,PER-
SONALINJURYCANRESULT.
DONOTJUMPSTARTWHENBATTERYINDICA-
TORDOTISYELLOWORBRIGHTCOLOR.BAT-
TERYCANEXPLODE.
DONOTALLOWJUMPERCABLECLAMPSTO
TOUCHEACHOTHERWHENCONNECTED TOA
BOOSTERSOURCE.
DONOTUSEOPENFLAMENEARBATTERY.
REMOVEMETALLICJEWELRYWORNONHANDS
ORWRISTSTOAVOIDINJURYBYACCIDENTAL
ARCHINGOFBATTERYCURRENT.
WHEN USINGAHIGHOUTPUT BOOSTING
DEVICE,DONOTALLOWDISABLEDVEHICLE'S
BATTERY TOEXCEED 16VOLTS.PERSONAL
INJURYORDAMAGE TOELECTRICAL SYSTEM
CANRESULT.
CAUTION:Whenusinganothervehicleasa
booster,donotallowvehiclestotouch.Electrical
systemscanbedamagedoneithervehicle.
TOJUMPSTARTADISABLEDVEHICLE:
(1)Raisehoodondisabledvehicleandvisually
inspectenginecompartmentfor:
"Generatordrivebeltconditionandtension.
"Fuelfumesorleakage,correctifnecessary.
"Frozenbattery.
"Yelloworbrightcolortestindicator,ifequipped.
"Lowbatteryfluidlevel.
CAUTION:

Ifthecauseofstartin

problemondis-
abledvehicleIssevere,damageoboostervehicle
chargingsystemcanresult.
INDEX
BATTERYNEGATIVE
CABLE
Fig.1JumperCableClampConnections
TJ
(2)Whenusinganothervehicleasabooster
source,turnoffallaccessories,placegearselectorin
parkorneutral,setparkbrakeorequivalentand
operateengineat1200rpm.-
(3)Ondisabledvehicle,placegearselectorinpark
orneutralandsetparkbrakeorequivalent.Turn
OFFallaccessories.
(4)Connectjumpercablestoboosterbattery.RED
clamptopositiveterminal(+).BLACKclamptoneg-
ativeterminal(-).DONOTallowclampsatopposite
endofcablestotouch,electricalarcwillresult(Fig.
1).Reviewallwarningsinthisprocedure.
(5)Ondisabledvehicle,connectREDjumpercable
clamptobatterypositive(+)terminal.Connect
BLACKjumpercableclamptotheengineascloseto
thegroundcableconnectionaspossible(Fig.1).
CAUTION:Donotcrankstartermotorondisabled
vehicleformorethan15seconds,starterwillover-
heatandcouldfail.
(6)Allowbatteryindisabledvehicletochargeto
atleast12.4volts(75%charge)beforeattemptingto
startengine.Ifenginedoesnotstartwithin15sec-
onds,stopcrankingengineandallowstartertocool
(15min.),beforecrankingagain.
NEGATIVEJUMPER
CABLE
POSITIVEJUMPER

ZGOUND
ENGINE
CABLE
DONOTALLOWVEHICLESTOTOUCH

9100-3
page page
SERVICEPROCEDURES RECREATIONAL TOWING.................10
EMERGENCY TOWHOOKS................10 TOWINGRECOMMENDATIONS ..............9
HOISTINGRECOMMENDATIONS ...........10 VEHICLETOWING........................9
JUMPSTARTINGPROCEDURE ..............8

19. TJ
SERVICEPROCEDURES (Continued)
DISCONNECT CABLECLAMPSASFOLLOWS:
"DisconnectBLACK cableIclampfromengine
groundondisabledvehicle.
"WhenusingaBoostervehicle,disconnect
BLACKcableclampfrombatterynegativeterminal.
DisconnectREDcableclampfiombatterypositive
terminal.
"DisconnectREDcableclamfrombatteryposi-
tiveterminalondisabledvehicle.
i
TOWINGRECOMMENDATIONS
WARNING:DONOTATTACHSLING-TYPETOWING
EQUIPMENTTOTHEREAROF!ATJ.
WhentowingaTJusinga!wheel-lift,orwhen
sling-typetowingequipmentisAttachedtothefront
end,placetowdolliesundertheoppositeendofthe
vehicle.Towvehiclesequippedwithaflat-bedcan
alsobeusedtotransportadisabledvehicle(Fig.2).
FLATBED
19500-6
Fig.2TowVehiclesWithApptovedEquipment
SAFETYPRECAUTIONS
"Securelooseandprotrudingparts.
"Alwaysuseasafetychainsystemthatisinde-
pendentoftheliftingandtowingequipment.
"Donotallowtowingequipmenttocontactthe
disabledvehicle'sfueltank.
LUBRICATIONANDMAINTENANCE

0-9
"Donotallowanyoneunderthedisabledvehicle
whileitisliftedbythetowingdevice.
"Donotallowpassengerstorideinavehicle
beingtowed.
"Alwaysobservestateandlocallawsregarding
towingregulations.
"Donottowavehicleinamannerthatcould
jeopardizethesafetyoftheoperator,pedestriansor
othermotorists.
"Donotattachtowchains,T-hooks,J-hooks,ora
towslingtoabumper,steeringlinkage,driveshafts
oranon-reinforcedframehole.
GROUNDCLEARANCE
CAUTION:Ifvehicleistowedwithwheels
removed,installlugnutstoretainbrakedrums.
Atowedvehicleshouldberaiseduntilliftedwheels
areaminimum100mm(4in)fromtheground.Be
surethereisadequategroundclearanceattheoppo-
siteendofthevehicle,especiallywhentowingover
roughterrainorsteeprisesintheroad.Ifnecessary,
removethewheelsfromtheliftedendofthevehicle
andlowerthevehicleclosertotheground,to
increasethegroundclearanceattheoppositeendof
thevehicle.Installlugnutsonwheelattachingstuds
toretainbrakedrums.
FLATBEDTOWINGRAMPANGLE
Ifavehiclewithflat-bedtowingequipmentisused,
theapproachrampangleshouldnotexceed15
degrees.
VEHICLETOWING
ChryslerCorporationrecommendsthata4WD
vehiclebetransportedonaflat-beddevice.AWheel-
liftorfrontendattachedSling-typedevicecanbe
usedprovidedallthewheelsareliftedofftheground
usingtowdollies.
TOWING-FRONT ENDLIFTED(WHEELLIFT)
(1)Raisetherearofthevehicleoffthegroundand
installtowdolliesunderrearwheels.
(2)Attachthewheellifttothefrontwheels.
TOWING-REAR ENDLIFTED(WHEELLIFT
ONLY)
(1)Raisethefrontofthevehicleofftheground
andinstalltowdolliesunderfrontwheels.
(2)Attachthewheellifttotherearwheels.

20. 0-10

LUBRICATIONANDMAINTENANCE
SERVICEPROCEDURES (Continued)
TOWING-FRONT ENDLIFTED(SLING-TYPE)
(1)Raisetherearofthevehicleoffthegroundand
installtowdolliesunderrearwheels.
(2)AttachT-hookstotheaccessholesontheout-
boardsideoftheframerails(Fig.3).
(3)Beforetighteningthechain,positionaprotec-
tivepadbetweenthechainandthebumper.
(4)Attachthesafetychainstothevehicle(Fig.

).
(5)TurntheignitionswitchtotheOFFpositionto
unlockthesteeringwheel.
(6)ShifttransfercasetoNEUTRAL.
THOOK'\

0

Al

'CHAIN
Fig.3T-HookAttachment
EMERGENCYTOW-HOOKS
Fig.4SafetyChainAttachment
RECREATIONALTOWING
RefertotheOwnersManualfortowingprocedures.
WARNING:REMAINATASAFEDISTANCEFROMA
VEHICLETHATISBEINGTOW~DVIAITSTOW
HOOKS.THETOWSTRAPSICHAI SCOULDBREAK
ANDCAUSESERIOUSINJURY.
TJ
SomeJeepvehiclesareequippedwithfrontemer-
gencytowhooks.Thetowhooksshouldbeusedfor
EMERGENCY purposesonly.
CAUTION:DONOTuseemergencytowhooksfor
towtruckhook-uporhighwaytowing.
HOISTINGRECOMMENDATIONS
RefertotheOwner'sManualforemergencyvehicle
liftingprocedures.
FLOORJACK
Whenproperlypositioned,afloorjackcanbeused
toliftaJeepvehicle(Fig.5).Supportthevehiclein
theraisedpositionwithjackstandsatthefrontand
rearendsoftheframerails.
DRIVE-ONHOIST
FRAMECONTACTHOIST
IIIII
"Anaxletube.
"Abodysidesill.
"Asteeringlinkage
Adriveshaft.
"Theengineortransmission
Thefueltank.
"Afrontsuspensionarm.
TWINPOSTCHASSISHOIST
"FLOORJACK
Fig.5VehicleLiftingLocations
CAUTION:DonotattempttoliftaJeep
withafloorlackpositionedunder:
component.
oilpan.
80a4d237
vehicle
NOTE:Usethecorrectsub-framerailorframerail
liftinglocationsonly.

21. TJ
SERVICEPROCEDURES (Continued)
HOIST
Avehiclecanbeliftedwith:
"Asingle-post,frame-contacthoist.
"Atwin-post,chassishoist.
"Aramp-type,drive-onhoist.
NOTE:Whenaframe-contacttypehoistIsused,
verifythattheliftingpadsarepositionedproperly.
WARNING:THEHOISTINGANDJACKLIFTING
POINTSPROVIDEDAREFORACOMPLETEVEHI-
-LUBRICATIONANDMAINTENANCE

0-11
CLE.WHENACHASSISORDRIVETRAINCOMPO-
NENTISREMOVED FROMAVEHICLE,THE
CENTEROFGRAVITYISALTEREDMAKINGSOME
HOISTINGCONDITIONSUNSTABLE.PROPERLY
SUPPORT ORSECUREVEHICLETOHOISTING
DEVICEWHENTHESECONDITIONSEXIST.

22. TJ
GENERALINFORMATION
WHEELALIGNMENT

......................

1
SERVICEPROCEDURES
ALIGNMENTMEASUREMENTS AND
GENERALINFORMATION
page
ALIGNMENT..............................1

REARSUSPENSION......................12
FRONTSUSPENSION......................6
WHEELALIGNMENT
Wheelalignmentinvolvesthecorrectpositioningof
thewheelsinrelationtothevehicle.Thepositioning
isaccomplishedthroughsuspensionandsteering
linkageadjustments.Analignmentisconsidered
essentialforefficientsteering,gooddirectionalstabil-
ityandtomaximizetirewear.Themostimportant
measurementsoffrontendalignmentarecaster,
camberandtoeposition.
NOTE:Routineinspectionofthefrontsuspension
andsteeringcomponentsisagoodpreventative
maintenancepractice.Inspectionalsohelpsto
ensuresafeoperationofthevehicle.
"CASTER istheforwardorrearwardtiltofthe
steeringknucklefromvertical.Tiltingthetopofthe
knucklerearwardprovidespositivecaster.Tiltingthe
topoftheknuckleforwardprovidesnegativecaster.
Casterisadirectionalstabilityangle.Thisangle
enablesthefrontwheelstoreturntoastraight
aheadpositionafterturns.
"CAMBER istheinwardoroutwardtiltofthe
wheelrelativetothecenterofthevehicle.Tiltingthe
SUSPENSION
CONTENTS
ALIGNMENT
INDEX
page
SUSPENSION2-1
page
page
ADJUSTMENTS ........................4
PRE-ALIGNMENT INSPECTION..............3
SPECIFICATIONS
ALIGNMENTSPECIFICATIONS ..............5
topofthewheelinwardprovidesnegativecamber.
Tiltingthetopofthewheeloutwardprovidespositive
camber.Incorrectcamberwillcausewearonthe
insideoroutsideedgeofthetire.Theangleisnot
adjustable,thedamagedcomponent(s)mustbe
replacedtocorrectmis-alignment.
"WHEEL TOEPOSITION isthedifference
betweentheleadinginsideedgesandtrailinginside
edgesofthefronttires.Incorrectwheeltoeposition
isthemostcommoncauseofunstablesteeringand
uneventirewear.Thewheeltoepositionisthefinal
frontwheelalignmentadjustment.
"STEERING AXISINCLINATION ANGLE is
measuredindegreesandistheanglethatthesteer-
ingknucklesaretilted.Theinclinationanglehasa
fixedrelationshipwiththecamberangle.Itwillnot
changeexceptwhenaspindleorballstudisdam-
agedorbent.Theangleisnotadjustable,thedam-
agedcomponent(s)mustbereplacedtocorrectmis-
alignment.
CAUTION:Donotattempttomodifyanysuspen-
sionorsteeringcomponentbyheatingandbend-
ing.

23. 2-2

SUSPENSION

TJ
SERVICEPROCEDURES (Continued)
CAMBER
WHEEL
TRUE~~ -
CENTERLINE
VERTICAL ~ii_ NEGATIVE
CAMBER
ANGLE
PIVOT
CENTERLINE
SCRUB
RADIUS
POSITIVECAMBER(NOTSHOWN)
TOPOFWHEELOUTBOARD
THRUSTANGLE
I
ANGLEOFREARAXLE
RELATIVETOVEHICLECENTERLINE
(+)AXLEPOINTSLEFT

(-)AXLEPOINTSRIGHT
WheelAlignmentMeasurements
J9402-57

24. TJ
SERVICE PROCEDURES
PRE-ALIGNMENTINSPECTION
Beforestartingwheelalignment,thefollowing
inspectionandnecessarycorrectionsmustbecom-
pleted.RefertoSuspensionanldSteeringSystem
DiagnosisChartforadditionalinformation.
(1)Tireswiththesamerecommendedairpressure,
size,andtreadwear.RefertoGroup22,Wheelsand
Tiresfordiagnosisinformation.
(2)Inspectfrontwheelbearingsforwearoradjust-
ment.
SuspensionAndSteeringSystemDiagnosis
SUSPENSION 2-3
(3)Inspectfrontwheelsforexcessiveradial,lat-
eralrunoutandunbalance.RefertoGroup22,
WheelsandTiresfordiagnosisinformation.
(4)Inspectballstuds,linkagepivotpointsand
steeringgearforlooseness,roughness,bindingora
stickingcondition.RefertoGroup19,Steeringfor
additionalinformation.
(5)Inspectsuspensioncomponentsforwearand
noise.RefertoSuspensionAndSteeringSystem
Diagnosisforadditionalinformation.Checkcompo-
nentsforcorrecttorque.
CONDITION POSSIBLECAUSES CORRECTION
FRONTENDNOISE 1.Looseorwornwheelbearings. 1.Adjustorreplacewheelbearings.
2.Looseorwornsteeringor 2.Tightenorreplacecomponentsas
suspensioncomponents necessary.
EXCESSIVEPLAYINSTEERING 1.Looseorwornwheelbearings. 1.Adjustorreplacewheelbearings.
2.Looseorwornsteeringor 2.Tightenorreplacecomponentsas
suspensioncomponents necessary.
3.Looseorwornsteeringgear. 3.Adjustorreplacesteeringgear.
FRONTWHEELSSHIMMY 1.Looseorwornwheelbearings. 1.Adjustorreplacewheelbearings.
2.Looseorwornsteeringor 2.Tightenorreplacecomponentsas
suspensioncomponents necessary.
3.Tireswornoroutofbalance. 3.Replaceorbalancetires.
4.Alignment. 4.Alignvehicletospecifications.
VEHICLEINSTABILITY 1.Looseorwornwheelbearings. 1.Adjustorreplacewheelbearings.
2.Looseorwornsteeringor 2.Tightenorreplacecomponentsas
suspensioncomponents necessary.
3.Tirepressure. 3.Adjusttirepressure.
4.Alignment. 4.Alignvehicletospecifications.
EXCESSIVESTEERINGEFFORT 1.Looseorwornsteeringgear. 1.Adjustorreplacesteeringgear.
2.Columncouplerbinding. 2.Replacecoupler.
3.Tirepressure. 3.Adjusttirepressure.
4.Alignment. 4.Alignvehicletospecifications.
VEHICLEPULLSTOONESIDE 1.Tirepressure. 1.Adjusttirepressure.
2.Alignment. 2.Alignvehicletospecifications.
3.Looseorwornsteeringor 3.Tightenorreplacecomponentsas
suspensioncomponents necessary.
4.Radialtirelead. 4.Rotateorreplacetireas
necessary.
5.Brakepull. 5.Repairbrake.asnecessary.

25. 2-4 SUSPENSION
SERVICEPROCEDURES (Continued)
ALIGNMENTMEASUREMENTSAND
ADJUSTMENTS
Beforeeachalignmentreadingthevehicleshouldbe
jounced(rearfirst,thenfront).Graspeachbumperat
thecenterandjouncethevehicleupanddownthree
times.Alwaysreleasethebumperinthedownposition.
CAMBER
Thewheelcamberangleispreset.Thisangleisnot
adjustableandcannotbealtered.
CASTER
Checkthecasterofthefrontaxleforcorrectangle.
Besuretheaxleisnotbentortwisted.Roadtestthe
vehicleandobservethesteeringwheelreturn-to-cen-
terposition.Lowcasterwillcausepoorsteering
wheelreturnability.
Duringtheroadtest,turnthevehicletoboththeleft
andright.Ifthesteeringwheelreturnstothecenter
positionunassisted,thecasterangleiscorrect.How-
ever,ifsteeringwheeldoesnotreturntowardthecenter
positionunassisted,alowcasterangleisprobable.
Castercanbeadjustedbylooseningandrotatingthe
camsonthelowersuspensionarm(Fig.1).Changing
casteranglewillalsochangethefrontpropeller
shaftangle.Thepropellershaftanglehaspriority
overcaster.RefertoGroup3,Differentialand
Drivelineforadditionalinformation.
AXLE
BRACKET
Fig.1CamAdjuster
BRACKET
REINFORCEMENT
LOWER
SUSPENSION
ARM
19302-59
TOEPOSITION
NOTE:Thewheeltoepositionadjustmentshould
bethefinaladjustment.
(1)Starttheengineandturnwheelsbothways
beforestraighteningthesteeringwheel.Centerand
securethesteeringwheel.
(2)Loosentheadjustmentsleeveclampbolts(Fig.
2).
(3)Adjusttherightwheeltoepositionwiththe
draglink(Fig.3).Turnthesleeveuntiltheright
wheelisatthecorrectpositiveTOE-IN position.
Positiontheclampboltsasshown(Fig.2)and
tightento49N-m(36ft.lbs.).Makesurethetoe
settingdoesnotchangeduringclamptighten-
ing.
COTTER

PITMAN
PIN DAMPENER ARM
Fig.2DragLinkandTieRodClamp
Fig.3SteeringLinkage
TJ
(4)Adjusttheleftwheeltoepositionwiththetie
rod.Turnthesleeveuntiltheleftwheelisatthe
sameTOE-INpositionastherightwheel.Position
theclampboltsasshown(Fig.2)andtightento27

26. TJ

SUSPENSION 2-5
SERVICEPROCEDURES (Continued)
N-m(20ft.lbs.).Makesurethetoesettingdoes

SPECIFICATIONS
notchangeduringclamptightening.
(5)Verifytherighttoesetting.

ALIGNMENTSPECIFICATIONS
ADJUSTMENT PREFERRED RANGE
CASTER 7° ±1.0°
CAMBER
(fixedangle)
-0.250 ±0.630
WHEELTOE-IN
(eachwheel)
0.15° ±0.15°
THRUST
ANGLE
0 ±0.15°

27. 2-6

SUSPENSION
DESCRIPTIONANDOPERATION
FRONTSUSPENSION .....................6
DIAGNOSISANDTESTING
SHOCKDIAGNOSIS ......................6
REMOVALANDINSTALLATION
AXLEBUSHING..........................8
COILSPRING...........................7
HUBBEARING..........................10
LOWERSUSPENSIONARM

................7
SHOCKABSORBER .......................7
DESCRIPTION ANDOPERATION
FRONTSUSPENSION
Thefrontsuspensionisalink/coildesigncom-
prisedof:
"Shockabsorbers
"Coilsprings
"Upperandlowersuspensionarms
"Stabilizerbar
"Trackbar
Link/CoilSuspension:Thelink/coilsuspension
allowseachwheeltoadapttodifferentroadsurfaces
withoutgreatlyaffectingtheoppositewheel.Wheelsare
attachedtoahub/bearingswhichboltstotheknuckles.
Thehub/bearingisnotserviceableandisreplacedasa
unit.Steeringknucklespivotonreplaceableballstuds
attachedtotheaxletubeyokes.
ShockAbsorbers:Theshockabsorbersdampen
jounceandreboundmotionofthevehicleovervari-
ousroadconditions.Thetopoftheshockabsorbers
areboltedtoaframebracket.Thebottomofthe
shocksareboltedtotheaxlebrackets.
CoilSprings:Thecoilspringscontrolridequality
andmaintainproperrideheight.Thecoilsprings
mountupinthewheelhouse.Arubberdoughnutiso-
latorislocatedbetweenthetopofthespringandthe
frame.Thebottomofthespringseatsonaaxlepad
andisretainedwithaclip.
UpperAndLowerSuspension:Thesuspension
armsusebushingstoisolateroadnoise.Thesuspen-
sionarmsareboltedtotheframeandaxlethrough
therubberbushings.Thelowersuspensionarmuses
camboltsattheaxletoallowforcasterandpinion
angleadjustment.Thesuspensioarmtravelislim-
itedthroughtheuseofjouncebmpersincompres-
sionandshocksabsorbersinrebund.
StabilizerBar:Thestabilizerbarisusedtocon-
trolvehiclebodyrollduringturs.Thespringsteel.
FRONT SUSPENSION
page
INDEX
DIAGNOSIS ANDTESTING
TJ
page
STABILIZERBAR.........................9
STEERINGKNUCKLE .....................7
TRACKBAR.............................9
UPPERSUSPENSIONARM.................8
WHEELMOUNTINGSTUDS................10
SPECIFICATIONS
TORQUECHART........................11
SPECIALTOOLS
FRONTSUSPENSION ....................11
barhelpstocontrolthevehiclebodyinrelationship
tothesuspension.Thebarextendsacrossthetopof
thechassisframerails.Stabilizerbarmountsareiso-
latedbyrubberbushings.Linksareconnectedfrom
thebartotheaxlebrackets.
TrackBar:Thetrackbarisusedtocontrolfront
axlelateralmovement.Thebarisattachedtoa
framerailbracketwithaballstudandisolatedwith
abushingattheaxlebracket.
NOTE:Periodiclubricationofthefrontsuspension
(steering)systemcomponentsisrequired.Rubber
bushingsmustneverbelubricated.RefertoGroup
0,LubricationAndMaintenancefortherecom-
mendedmaintenanceschedule.
CAUTION:Suspensioncomponentswithrubberbush-
ingsshouldbetightenedwiththevehicleatnormal
height.Itisimportanttohavethespringssupporting
theweightofthevehiclewhenthefastenersare
torqued.Ifspringsarenotattheirnormalrideposi-
tion,vehicleridecomfortcouldbeaffectedandprema-
turebushingwearmayoccur.
SHOCKDIAGNOSIS
Anoisefromashockabsorbermaybecausedby
movement betweenmountingbushingsandmetal
bracketsorattachingcomponents.Thisnoisecan
usuallybestoppedbytighteningtheattachingnuts.
Ifthenoisepersists,inspectfordamagedandworn
bushings,andattachingcomponents.Repairasnec-
essaryifanyoftheseconditionsexist.
Theshockabsorbersarenotrefillableoradjust-
able.Ifamalfunctionoccurs,theshockabsorber

28. TJ
DIAGNOSIS ANDTESTING (Continued)
mustbereplaced.Totestashockaabsorber,holditin
anuprightpositionandforcethepistoninandoutof
thecylinderfourorfivetimes.Theactionthroughout
eachstrokeshouldbesmoothandeven.
Theshockabsorberbushingscoonotrequireany
typeoflubrication.Donotattempttostopbushing
noisebylubricatingthem.Greaseandmineraloil-
baselubricantswilldeterioratethebushingrubber.
REMOVALANDINSTALLATION
SHOCKABSORBER
REMOVAL
(1)Removethenut,retainerandgrommet
theupperstudthroughenginecompartmentaccess
hole(Fig.1).
FRONTAXLE
Fig.1CoilSpring&ShockAbsorber
COILSPRING
from
80632206
(2)Removethelowernutsandboltsfromtheaxle
bracketandremovetheshockabsorber.
INSTALLATION
(1)Positionthelowerretainerandgrommetonthe
upperstud.Inserttheshockabsorberthroughthe
shockbrackethole.
(2)Installthelowerboltsandnuts.Tightennuts
to28N-m(250in.lbs.).
(3)Installtheuppergrommetand,retaineronthestud
andinstallthenutandtightento23N-m(17ft.lbs.).
REMOVAL
(1)Raiseandsupportthevehicle.Positiona
hydraulicjackundertheaxletosupportit.
SUSPENSION2-7
(2)Paintorscribealignmentmarksonthecam
adjustersandaxlebracketforinstallationreference.
(3)Markanddisconnectthefrontpropellershaft
fromtheaxle.
(4)Removethelowersuspensionarmnut,cam
andcamboltfromtheaxle.
(5)Disconnectthestabilizerbarlinksandshock
absorbersfromtheaxle.
(6)Disconnectthetrackbarfromtheframerail
bracket.
(7)Disconnectthedraglinkfromthepitmanarm.
(8)Lowertheaxleuntilthespringisfreefromthe
uppermount.Removethecoilspringretainerbolt
andremovethespring.
(9)Removethejouncebumperifnecessaryfrom
theupperspringmount.
INSTALLATION
(1)Positionthecoilspringontheaxlepad.Install
thespringretainerandboltandtightento22N-m
(16ft.lbs.).
(2)Installthejouncebumper.
(3)Raisetheaxleintopositionuntilthespring
seatsintheuppermount,thenraiseanother51mm
(2in.).
(4)Connectthestabilizerbarlinksandshock
absorberstotheaxlebracket.Connectthetrackbar
totheframerailbracket.
(5)Installthelowersuspensionarmtotheaxle.
(6)Installthefrontpropellershafttotheaxle.
(7)Installdraglinktopitmanarm.
(8)Removethesupportsandlowerthevehicle.
(9)Tightenallsuspensioncomponentstoproper
torque.
STEERINGKNUCKLE
Forserviceproceduresonthesteeringknuckleand
ballstudsrefertoGroup3DifferentialsAndDriv-
eline.
LOWERSUSPENSIONARM
REMOVAL
(1)Raiseandsupportthevehicle.
(2)IfequippedwithABSbrakesremovesensor
wirefromtheinboardsideofthearm.
(3)Paintorscribealignmentmarksonthecam
adjustersandsuspensionarmforinstallationrefer-
ence(Fig.2).
(4)Removethelowersuspensionarmnut,cam
andcamboltfromtheaxle(Fig.3).
(5)Removethenutandboltfromtheframerail
bracketandremovethelowersuspensionarm(Fig.3).
INSTALLATION
(1)Positionthelowersuspensionarmintheaxle
bracketandframerailbracket.

29. 2-8

SUSPENSION
REMOVALANDINSTALLATION (Continued)
AXLE
BRACKET
LOWER
SUSPENSION
ARM
Fig.2CamAdjuster
UPPER
SUSPENSION
ARM
BRACKET
REINFORCEMENT
LOWER
SUSPENSION
ARM
J9302-59
Fig-3Upper&LowerSuspensionArms
80a13812
NOTE:Smallholesinthesideofthearmface
inboard.
(2)Installtherearboltandneatfingertighten.
(3)Installnewcamboltandnewnutfinger
tightenintheaxleandalignthereferencemarks.
(4)IfequippedwithABSbrakesinstallsensor
wiretotheinboardsideofthearmwithnewclips.
(5)Lowerthevehicle.
(6)Tightenaxlebracketnutto115N-m(85ft.
lbs.).
(7)Tightenframebracketnutito176N-m(130ft.
lbs.).
(8)Alignthevehicle.
UPPERSUSPENSIONARM
REMOVAL
(1)Raiseandsupportthevehicle.
(2)Removetheuppersuspensionarmnutandbolt
atthe,axlebracket(Fig.3).
(3)Removethenutandboltattheframerailand
removetheuppersuspensionarm.
INSTALLATION
(1)Positiontheuppersuspensionarmattheaxle
andframerail.
(2)Installtheboltsandfingertightenthenuts.
(3)Removethesupportsandlowerthevehicle.
(4)Tightenthenutattheaxleandframebrackets
to75N-m(55ft.lbs.).
AXLEBUSHING
REMOVAL
(1)Removetheuppersuspensionarmfromaxle
(2)PositionReceiver7932-1(J-35581-1)overthe
bushingintheaxleandinstallBushingRemoval/In-
staller(Fig.4).
(3)RemovethebushingbytighteningtheLong
Nut.
SPECIAL
TOOL
7932-1
(J-35581-1)
ti
SPECIAL
TOOL
7603
J-21474-18)
Fig.4BushingRemoval
AXLE
SPECIAL
BRACKET
TOOL
7604
TJ
(J-21474-19)
SPECIAL
TOOL
7932-2
(J-35581-2)
J9302-9
NOTE:Fortwo-wheeldriveaxlesandrightsideon
Model30axle,donotremoveReceiver7932-1
(J-35581-1)atthistime.
INSTALLATION
(1)Positionnewbushing,ReceiverandInstaller
onaxle(Fig.5).

30. TJ
REMOVAL ANDINSTALLATION (Continued)
(2)InstallthebushingbytighteningtheLongNut.
SPECIAL
TOOL
7603
(J-21474-18)
-SPECIAL
TOOL
7932-2
()-35581-2)
O
BRACKET
Fig.5BushingInstallation
AXLE SPECIAL
TOOL
7604
(J-21474-19)
SPECIAL
TOOL
7932-1
(J-35581-1)
J9302-8
(3)Removetoolsandinstalltheuppersuspension
arm.
STABILIZERBAR
REMOVAL
(1)Removeupperlinknuts(Fig.6)andseparate
thelinksfromthestabilizerbarwithRemove
MB-990635.
(2)Removefrontbumpervalence,refertoGroup
23Bodyforprocedure.
(3)Removestabilizerretainerbolts(Fig.6)and
removeretainers.
(4)Removestabilizerbar.
(5)Removelowerlinknutsandboltsandremove
links(Fig.6).
INSTALLATION
(1)Centerstabilizerbarontopoftheframerails
andinstallretainersandbolts.Tightenboltsto54
N-m(40ft.lbs.).
(2)Positionlinksonaxlebracketsandintothe
stabilizerbar.Installlowerlinkboltsandnutsand
tightento95N-m(70ft.lbs.).
(3)Installupperlinknutsandtightento61N-m
(45ft.lbs.).
(4)Installbumpervalence.
TRACKBAR
CAUTION :Useauniversalpuller,,tooltoseparate
thetrackbarballstudfromtheframerailbracket.
Thiswillpreventdamage tothebailstudseal.
SUSPENSION

2-9
REMOVAL
(1)Raiseandsupportthevehicle.
(2)Removethecotterpinandnutfromthe
studendattheframerailbracket(Fig.7).
(3)Useauniversalpullertooltoseparate
trackbarballstudfromtheframerailbracket.
(4)Removetheboltandflagnutfromthe
bracket(Fig.7).Removethetrackbar.
Fig.6StabilizerBar
Fig.7TrackBar
ball
the
axle
INSTALLATION
(1)Installthetrackbarataxletubebracket.
Looselyinstalltheretainingboltandflagnut.
(2)Itmaybenecessarytoprytheaxleassembly
overtoinstallthetrackbarattheframerail.Install
trackbarattheframerailbracket.Installthe
retainingnutonthestud.
(3)Tightentheballstudnutto88N-m(65ft.lbs.)
andinstallanewcotterpin.
(4)Removethesupportsandlowerthevehicle.
(5)Tightentheboltattheaxlebracketto75N-m
(55ft.lbs.).

31. 2-10

SUSPENSION
REMOVALANDINSTALLATION(Continued)
(6)Checkalignmentifanewtrackbarwas

WHEELMOUNTINGSTUDS
installed.
REMOVAL
(1)Raiseandsupportvehicle.
TheHubBearingisservicedasanassembly.

(2)Removewheelandtireassembly.
(3)Removebrakecaliperandrotor,referto
REMOVAL

5Brakesforprocedure.
(1)Raiseandsupportthevehicle.

(4)Removestudfromhubwith
(2)Removethewheelandtireassembly.

(Fig.9).
(3)Removethebrakecomponentsfromtheaxle,
refertoGroup5Brakes.
(4)Removethecotterpin,nutretainerandaxle
hubnut(Fig.8).
(5)Removethehubmountingboltsandremove
hubbearingfromthesteeringknuckleandaxle
shaft.
HUBBEARING
INSTALLATION
(1)Installthehubbearingandbrakedustshield
totheknuckle.
(2)Installthehubtoknuckleboltsandtightento
102N-m(75ft.lbs.).
(3)Installthehubwasherandnut.Tightenthe
hubnutto237N-m(175ft.lbs.).Installthenut
retainerandanewcotterpin.
(4)Installthebrakecomponents,refertoGroup5
Brakes.
(5)Installthewheelandtireassembly.
(6)Removesupportandlowerthevehicle.
STEERING
Fig.8HubBearing&Knuckle
Fig.9WheelStudRemoval
INSTALLATION
(1)Installnewstudintohubflange.
(2)Installthreewasherontostud,theninstalllug
nutwiththeflatsideofthenutagainstthewashers.
(3)Tightenlugnutuntilthestudispulledinto
thehubflange.Verifythatthestudisproperly
seatedintotheflange.
BRAKE WASHER
SHIELD
Group
RemoverC-4150A
HUBAND
BEARING
KNUCKLE

ASSEMBLY NUT J9302-43
TJ
8031e853
RETAINER
COTTERPIN

32. TJ
REMOVAL ANDINSTALLATION (Continued)
(4)Removelugnutandwashers.
(5)Installthebrakerotorandcaliper,referto
Group5Brakesforprocedure.
(6)Installwheelandtireassembly,usenewlug
nutonstudorstudsthatwerereplaced.
(7)Removesupportandlowervehicle.
SPECIFICATIONS
TORQUECHART
DESCRIPTION TORQUE
ShockAbsorber
UpperNut.................23N-m(17ft.lbs.)
LowerNut................28N-m(250in.lbs.)
SuspensionArmLower
AxleBracketNut...........115N-m(85ft.lbs.)
FrameBracketNut........176N-m(130ft.lbs.)
SuspensionArmUpper
AxleBracketNut............'75N-m(55ft.lbs.)
FrameBracketBolt..........75N-m(55ft.lbs.)
StabilizerBar
RetainerBolts..............54N-m(40ft.lbs.)
LinkUpperNut.............61N-m(45ft.lbs.)
LinkLowerBolt............95N-m(70ft.lbs.)
TrackBar
BallStudNut..............88N-m(65ft.lbs.)
AxleBracketBolt...........75N-m(55ft.lbs.)
SPECIAL TOOLS
FRONTSUSPENSION
Remover/InstallerSuspensionBushing7932
(J-35581)
Nut,Long7603(J-21474-18)
Bolt,Special7604(J-21474-19)
RemoverC-4150A
SUSPENSION

2-11
RemoverTieRodEndMB-990635

33. 2-12

SUSPENSION
DESCRIPTIONANDOPERATION
REARSUSPENSION .....................12
DIAGNOSISANDTESTING
SHOCKDIAGNOSIS......................12
REMOVALANDINSTALLATION
COILSPRING....
...........
..
......
.
...
13
LOWERSUSPENSIONARM................13
DESCRIPTION ANDOPERATION
REARSUSPENSION
Therearsuspensionislink/coildesigncomprised
of-
"Dual-actionshockabsorbers
"Coilsprings
"Upperandlowersuspensionarms
"Stabilizerbar
"Trackbar
ShockAbsorbers:Theshockabsorbersdampen
jounceandreboundofthevehicleovervariousroad
conditions.Thetopoftheshockabsorbersarebolted
totheframe.Thebottomoftheshocksareboltedto
axlebrackets.
CoilSprings:Thecoilspringscontrolridequality
andmaintainproperrideheight.Thespringsmount
betweenthebottomoftheframerailandtherear
axle.
UpperAndLowerSuspension:Thesuspension
armsusebushingstoisolateroadnoise.Thesuspen-
sionarmsareboltedtotheframeandaxlethrough
therubberbushings.Theuppersuspensionarmhas
provisionfortheuseofcamboltsattheaxletoallow
forpinionangleorthrustangleadjustment.The
camsareavailableasaservicekitandarenot
installedatthefactory.Thesuspensionarmtravelis
limitedthroughtheofusejouncebumpersincom-
pressionandshockabsorbersinrebound.
StabilizerBar:Thestabilizerbarisusedtocon-
trolvehiclebodyrollduringturns.Thespringsteel
barhelpstoequalizethevehiclebodyinrelationship
tothesuspension.Thebarextendsacrosstheunder-
sideofthechassisandmountstotherearaxle.Links
areconnectedfromthebartoframebrackets.The
barisisolatedbyrubberbushings.
TrackBar:Thetrackbarissedtocontrolrear
axlelateralmovement.Thetrackbarisattachedtoa
framerailbracketandanaxlebracket.Itisisolated
withbushingsatbothends.

I
REAR SUSPENSION
page
INDEX
DIAGNOSIS ANDTESTING
REMOVAL ANDINSTALLATION
SHOCKABSORBER
TJ
page
SHOCKABSORBER ......................12
STABILIZERBAR........................14
TRACKBAR............................15
UPPERSUSPENSIONARM................13
SPECIFICATIONS
TORQUECHART........................15
CAUTION:Suspensioncomponentsthatuserubber
bushingsshouldbetightenedwiththevehicleat
normalrideheight.Thiswillpreventprematurefail-
ureofthebushingandmaintainridecomfort.Rub-
berbushingsmustneverbelubricated.
SHOCKDIAGNOSIS
Anoisefromashockabsorbermaybecausedby
movement betweenmountingbushingsandmetal
bracketsorattachingcomponents.Thisnoisecan
usuallybestoppedbytighteningtheattachingnuts.
Ifthenoisepersists,inspectfordamagedandworn
bushings,andattachingcomponents.Repairasnec-
essaryifanyoftheseconditionsexist.
Theshockabsorbersarenotrefillableoradjust-
able.Ifamalfunctionoccurs,theshockabsorber
mustbereplaced.Totestashockabsorber,holditin
anuprightpositionandforcethepistoninandoutof
thecylinderfourorfivetimes.Theactionthroughout
eachstrokeshouldbesmoothandeven.
Theshockabsorberbushingsdonotrequireany
typeoflubrication.Donotattempttostopbushing
noisebylubricatingthem.Greaseandmineraloil-
baselubricantswilldeterioratethebushingrubber.
REMOVAL
(1)Raiseandsupportthevehicleandtheaxle.
(2)Removetheuppermountingbolts(Fig.1).
(3)Removethelowernutandboltfromtheaxle
bracket.Removetheshockabsorber.

34. TJ
REMOVAL ANDINSTALLATION (Continued)
AXLEBRACKET
COILSPRING
Fig.1ShockAbsorber
INSTALLATION
(1)Installtheshockabsorberontheupperframe
railandinstallmountingbolts.
(2)Tightentheupperboltsto31N-m(23ft.lbs.).
(3)Installlowerboltandnutfingertight.
(4)Removethesupportsandlowerthevehicle.
(5)Tightenthelowernutto100N-m(74ft.lbs.).
REMOVAL
(1)Raiseandsupportthevehicle.Positiona
hydraulicjackundertheaxletosupportit.
(2)Disconnectthestabilizerbarlinksandshock
absorbersfromtheaxlebrackets.
(3)Disconnectthetrackbarfromtheframerail
bracket.
(4)Lowertheaxleuntilthespringisfreefromthe
uppermountseatandremovethespring.
INSTALLATION
(1)Positionthecoilspringontheaxlepad.
(2)Raisetheaxleintopositionuntilthespring
seatsintheuppermount.
(3)Connectthestabilizerbarlinksandshock
absorberstotheaxlebracket.Connectthetrackbar
totheframerailbracket.
(4)Removethesupportsandlowerthevehicle.
(5)Tightenthestabilizerbarlinks,shockabsorb-
ersandtrackbartospecifiedtorque.
LOWERSUSPENSIONARM
REMOVAL
(1)Raiseandsupportthevehicle.
(2)Removethelowersuspensionarmnutandbolt
attheaxlebracket(Fig.2).
(3)Removethenutandboltattheframerail
mount(Fig.3)andremovethelowersuspensionarm.
UPPERSUSPENSIONARM
LOWER
SUSPENSION
ARM
INSTALLATION
LOWER
SUSPENSION
ARM
UPPERSUSPENSIONARM
SUSPENSION 2-13
Fig.2Upper&LowerSuspensionArms
FRAMEMOUNT

UPPER
SUSPENSION
ARM
Fig.3Upper&LowerSuspensionArms
80a13815
80a13816
(1)Positionthelowersuspensionarmintheaxle
bracketandframerailmount.
(2)Installthemountingboltsandfingertighten
thenuts.
(3)Removethesupportsandlowerthevehicle.
(4)Tightenthelowersuspensionarmnutsto177
N-m(130ft.lbs.).
REMOVAL
(1)Raiseandsupportthevehicle.
(2)Removetheparkingbrakecable/bracketand
ABSwiringbracketfromthearmifequipped(Fig.
4).
(3)Removetheuppersuspensionarmnutandbolt
fromtheaxlebracket(Fig.2).
(4)Removethenutandboltfromtheframerail
bracket(Fig.3)andremovetheuppersuspension
arm.

35. 2-14 SUSPENSION
REMOVAL ANDINSTALLATION (Continued)
PARKINGBRAKE
CABLE
BRACKET
UPPER
SUSPENSION
ARM
WIRING
BRACKET
80alc39b
Fig.4ParkingBrakeCable/BracketAndWiring
Bracket
INSTALLATION
(1)Positiontheuppersuspensionarmintheaxle
bracketandframerailbracket.
(2)Installtheboltsandfingertightenthenuts.
(3)Installtheparkingbrakecable/bracketand
ABSwiringbracketonthearmifequipped.
(4)Removethesupportsandlowerthevehicle.
(5)Tightentheuppersuspensionarmframerail
bracketboltto75N-m(55ft.lbs.).
(6)Tightentheuppersuspensionarmaxlebracket
nutto75N-m(55ft.lbs.).
STABILIZERBAR
REMOVAL
(1)Raiseandsupportthevehicle.
(2)Removethestabilizerbarlinkboltsfromthe
framemounts(Fig.5).
(3)Removethelinkboltsfrom,thestabilizerbar.
(4)Removethestabilizerbar,retainerboltsand
retainersfromtheaxlemounts(Fig.6)andremove
thebar.
INSTALLATION
(1)Installthestabilizerbarontheaxlemounts
andinstalltheretainersandbolts.
NOTE:

Ensurethebariscenteredwithequalspac-
ingonbothsidesandispositionedabovethedif-
ferentialhousing(Fig.6).
TJ
BAR 80.13814
Fig.5StabilizerBarLink
Fig.6StabilizerBar
STABILIZER
(2)Tightentheretainerboltsto54N-m(40ft.
lbs.).
(3)Installthelinksontothestabilizerbarand
framemounts.Installtheboltsandnutsfingertight.
(4)Removesupportandlowervehicle.
(5)Tightenthelinknuts/boltsto54N-m(40ft.
lbs.).

36. TJ
REMOVAL ANDINSTALLATION (Continued)
TRACKBAR
REMOVAL
(1)Raiseandsupportthevehicle.
(2)Removetheboltandnutfromtheframerail
bracket(Fig.7).
(3)Removetheboltfromtheaxlebracket(Fig.7)
andremovethetrackbar.
TRACKBAR
Fig.7RearTrackBar
REARAXLE

80a13811
INSTALLATION
(1)Installthetrackbarintheaxlebracketand
installtheboltloosely.
(2)Installthetrackbarintheframerailbracket
andlooselyinstalltheboltandnut.
NOTE:Itmaybenecessarytoprytheaxleassem-
blyovertoinstallthetrackbar.
(3)Removesupportsandlowerthevehicle.
(4)Tightenthetrackbarnut/boltatbothendsto
100N-m(74ft.lbs.).
SPECIFICATIONS
TORQUECHART
SUSPENSION

2-15
DESCRIPTION TORQUE
ShockAbsorber
UpperBolts................31N-m(23ft.lbs.)
LowerNut................100N-m(74ft.lbs.)
SuspensionArmLower
AxleBracketNut..........177N-m(130ft.lbs.)
FrameBracketNut........177N-m(130ft.lbs.)
SuspensionArmUpper
AxleBracketNut............75N-m(55ft.lbs.)
FrameBracketBolt..........75N-m(55ft.lbs.)
StabilizerBar
RetainerBolts..............54Ym(40ft.lbs.)
LinkNut/Bolt..............54N-m(40ft.lbs.)
TrackBar
FrameBracketNut.........100N-m(74ft.lbs.)
AxleBracketBolt..........100N-m(74ft.lbs.)

37. TJ
ANTILOCKBRAKES..........
GENERALINFORMATION
BRAKESYSTEM............
SERVICEWARNINGS&CAUTIO
DESCRIPTIONANDOPERATION
BRAKEHOSESANDLINES....
BRAKEPEDAL..............
COMBINATIONVALVE........
FRONTDISCBRAKES........
MASTERCYLINDER.........
PARKINGBRAKE............
POWERBRAKEBOOSTER ....
REARDRUMBRAKE.........
REDBRAKEWARNINGLAMP..
STOPLAMPSWITCH.........
DIAGNOSISANDTESTING
BASEBRAKESYSTEM.......
BRAKEDRUM..............
BRAKEFLUIDCONTAMINATION
BRAKELINEANDHOSES.....
COMBINATIONVALVE........
DISCBRAKEROTOR.........
MASTERCYLINDER/POWER BO
PARKINGBRAKE
CONTENTS
page
............30

BASEBRAKESYSTEM.....................1
BASEBRAKESYSTEM
page
.............2
NS..........2
.............6
.............2
.............4
.............4
.............3
.............5
.............4
.............2
.............2
.............6
............10
............11
............11
.............9
............10
OSTER.......9
11
REDBRAKEWARNINGLAMP...I1
...
.....
..
...8
STOPLAMPSWITCH......................8
SERVICEPROCEDURES
BRAKEBLEEDING..........
.I
............12
BRAKEDRUMMACHINING....,............

13
BRAKEFLUIDLEVEL.........',............

12
BRAKELINE...........................13
DISCROTORMACHINING.................
II

12
MASTERCYLINDER.....................12
BRAKES
INDEX
BRAKES

5-1
page
page
REMOVALANDINSTALLATION
BRAKEPEDAL..........................14
COMBINATIONVALVE....................15
DISCBRAKECALIPER...................17
DISCBRAKEROTOR.....................19
DISCBRAKESHOES.....................17
DRUMBRAKESHOES....................19
MASTERCYLINDER.....................16
PARKINGBRAKEHANDLEVER............21
POWERBRAKEBOOSTER ................16
REARPARKINGBRAKECABLE.............21
STOPLAMPSWITCH.....................14
WHEELCYLINDER ......................20
DISASSEMBLYANDASSEMBLY
DISCBRAKECALIPER...................23
MASTERCYLINDERRESERVOIR ...........22
WHEELCYLINDER

......................25
CLEANINGANDINSPECTION
CALIPER..............................25
REARDRUMBRAKE.....................26
WHEELCYLINDER

......................26
ADJUSTMENTS
PARKINGBRAKECABLETENSIONER

.......27
REARDRUMBRAKE.....................27
STOPLAMPSWITCH.....................26
SPECIFICATIONS
BRAKECOMPONENTS ...................28
BRAKEFLUID..........................28
TORQUECHART........................29
SPECIALTOOLS
BASEBRAKES..........................29

38. 5-2

BRAKES
GENERALINFORMATION
BRAKESYSTEM
Powerassistfrontdiscandreardrumbrakesare
standardequipment.Discbrakecomponentsconsist
ofsinglepistoncalipersandventilatedrotors.Rear
drumbrakesaredualshoeunitswithcastbrake
drums.
Theparkingbrakemechanismisleverandcable
operated.Thecablesareattachedtoleversonthe
reardrumbrakesecondaryshoes.Theparking
brakesareoperatedhandlever.
Adualdiaphragmvacuumpowerbrakeboosteris
usedforallapplications.Allmodelshaveatwo-piece
mastercylinderwithplasticreservoir.
Allmodelsareequippedwithacombinationvalve.
Thevalvecontainsapressuredifferentialvalveand
switchandafixedraterearproportioningvalve.
Factorybrakeliningonallmodelsconsistsofan
organicbasematerialcombinedwithmetallicparti-
cles.Theliningdoesnotcontainasbestos.
SERVICEWARNINGS&CAUTIONS
WARNING:FACTORYINSTALLEDBRAKELININGS
DONOTCONTAINASBESTOS FIBERS.DUSTAND
DIRTACCUMULATING ONBRAKEPARTSDURING
NORMAL USEMAYCONTAINASBESTOS FIBERS
FROMAFTERMARKETBRAKELININGS.BREATH-
INGEXCESSIVECONCENTRATIONS OFASBESTOS
FIBERSCANCAUSESERIOUSBODILYHARM.
EXERCISE CARE WHEN SERVICING BRAKE
PARTS.DONOTCLEANBRAKE,PARTSWITHCOM-
PRESSEDAIRORBYDRYBRUSHING.USEAVAC-
UUMCLEANER SPECIFICALLY DESIGNED FOR
THEREMOVAL OFASBESTOS FIBERSFROM
BRAKECOMPONENTS .IFASUITABLEVACUUM
CLEANERISNOTAVAILABLE,CLEANINGSHOULD
BEDONEWITHAWATERDAMPENED CLOTH.DO
NOTSAND,ORGRINDBRAKELININGUNLESS
EQUIPMENTUSEDISDESIGNEDTOCONTAINTHE
DUSTRESIDUE.DISPOSEOFALLRESIDUECON-
TAININGASBESTOS FIBERSINSEALEDBAGSOR
CONTAINERS TOMINIMIZEEXPOSURE TOYOUR-
SELFANDOTHERS.FOLLOW PRACTICES PRE-
SCRIBEDBYTHEOCCUPATIONAL SAFETYAND
HEALTHADMINISTRATION ANDTHEENVIRONMEN-
TALPROTECTION AGENCYFORTHEHANDLING,
PROCESSING, ANDDISPOSITIONOFDUSTOR
DEBRISTHATMAYCONTAINASBESTOSFIBERS.
CAUTION:Neverusegasoline,kerosene,alcohol,
motoroil,transmissionfluid,oranyfluidcontaining
mineraloiltocleanthesystemcomponents.These
fluidsdamagerubbercupsandseals.Useonly
freshbrakefluidorMoparbrakecleanertocleanor
TJ
flushbrakesystemcomponents.Thesearetheonly
cleaningmaterialsrecommended.Ifsystemcontam-
inationissuspected,checkthefluidfordirt,discol-
oration,orseparationintodistinctlayers.Drainand
flushthesystemwithnewbrakefluidifcontamina-
tionissuspected.
CAUTION:UseMoparbrakefluid,oranequivalent
qualityfluidmeetingSAE/DOTstandardsJ1703and
DOT3.Brakefluidmustbecleanandfreeofcon-
taminants.Usefreshfluidfromsealedcontainers
onlytoensureproperantilockcomponentopera-
tion.
CAUTION:UseMoparmulti-mileageorhightemper-
aturegreasetolubricatecaliperslidesurfaces,
drumbrakepivotpins,andshoecontactpointson
thebackingplates.Usemulti-mileagegreaseorGE
661orDow111siliconegreaseoncaliperbushings
andslidepinstoensureproperoperation.
DESCRIPTIONANDOPERATION
BRAKEPEDAL
Asuspended-typebrakepedalisused,thepedal
pivotsonashaftmountedinthepedalsupport
bracket.Thebracketisattachedtothedashpanel.
Thebrakepedalisaserviceablecomponent.The
pedal,pedalbushingsandshaftareallreplaceable
parts.Thepedalbracketcanalsobereplacedwhen
necessary.
STOPLAMPSWITCH
Theplungertypestoplampswitchismountedona
bracketattachedtothebrakepedalsupport.The
switchcanbeadjustedwhennecessary.
REDBRAKEWARNINGLAMP
Aredwarninglampisusedfortheservicebrake
portionofthehydraulicsystem.Thelampislocated
intheinstrumentcluster.
Theredwarninglightalertsthedriverifapres-
suredifferentialexistsbetweenthefrontandrear
hydraulicsystems.Thelightalsoalertsthedriver
whentheparkingbrakesareapplied.
POWERBRAKEBOOSTER
Theboosterassemblyconsistsofahousingdivided
intoseparatechambersbytwointernaldiaphragms.
Theouteredgeofeachdiaphragmisattachedtothe
boosterhousing.Thediaphragmsareconnectedto
theboosterprimarypushrod.
Twopushrodsareusedinthebooster.Thepri-
marypushrodconnectstheboostertothebrake

39. TJ
DESCRIPTIONANDOPER
pedal.Thesecondarypushrodc
tothemastercylindertostroket
Theatmosphericinletvalveis
bytheprimarypushrod.Booste
throughahoseattachedtoanint
atoneendandtothebooster
other.Thevacuumcheckvalvein
isaone-waydevicethatprevents
Powerassistisgeneratedbyu
differentialbetweennormalat
andavacuum.Thevacuumneed
ationistakendirectlyfromthe
fold.Theentrypointforatmo
throughafilterandinletvalve
housing(Fig.1).
Thechamberareasforward
phragmsareexposedtovacuu
manifold.Thechamberareasto
VACUUM
CHECK
VALVE
MASTER
CYLINDER
MOUNTING
STUD(2)
FRONT
DIAPHRAGM
SECONDARY
PUSHROD
(TOMASTER
CYLINDER)
nnectsthebooster
ecylinderpistons.
openedandclosed
vacuumsupplyis
kemanifoldfitting
heckvalveatthe
heboosterhousing
vacuumleakback.
lizingthepressure
osphericpressure
dforboosteroper-
ngineintakemani-
phericpressureis
attherearofthe
ftheboosterdia-
fromtheintake
herearofthedia-
Fig.1PowerBrakeBooster-Typical
phragms,areexposedtonormalatmosphericpres-
sureof101.3kilopascals(14.7pounds/squarein.).
Brakepedalapplicationcausestheprimarypush
rodtoopentheatmosphericinletvalve.Thisexposes
theareabehindthediaphragmstoatmosphericpres-
sure.Theresultingpressuredifferentialprovidesthe
extraapplypressureforpowerassist.
MASTERCYLINDER
Themastercylinderhasaremovablenylonreser-
voir(Fig.2).Thecylinderbodyismadeofaluminum
andcontainsaprimaryandsecondarypistonassem-
bly.Thecylinderbodyincludingthepistonassem-
bliesarenotserviceable.Ifdiagnosisindicatesan
internalproblemwiththecylinderbody,itmustbe
replacedasanassembly.Thereservoirandgrommets
aretheonlyreplaceablepartsonthemastercylinder.
HOUSING
BOOSTER
MOUNTING
STUDS(4)
SEAL
ATMOSPHERIC
INLETVALVE
ASSEMBLY
PRIMARY
PUSHROD
(TOBRAKE
PEDAL)
J9505-58

40. 5-4BRAKES
DESCRIPTIONANDOPERATION(Continued)
FLUID
LEVEL
MARKS
Fig.2MasterCylinder-Typical
RESERVOIR
J9505-17
COMBINATIONVALVE
Thecombinationvalvecontainsapressurediffer-
entialvalveandswitchandarearbrakeproportion-
ingvalve.Thevalveisnotrepairable.Itmustbe
replacedifdiagnosisindicatesthisisnecessary.
Thepressuredifferentialswitchisconnectedtothe
brakewarninglight.Theswitchisactuatedbymove-
mentoftheswitchvalve.Theswitchmonitorsfluid
pressureintheseparatefront/rearbrakehydraulic
circuits.
Adecreaseorlossoffluidpressureineitherhydraulic
circuitwillcausetheswitchvalvetoshuttletothelow
pressureside.Movementofthevalvepushestheswitch
plungerupward.Thisactionclosestheswitchinternal
contactscompletingtheelectricalcircuittothered
warninglight.Theswitchvalvewillremaininanactu-
atedpositionuntilrepairsaremade.
Therearproportioningvalveisusedtobalance
front-rearbrakeaction.Thevalveallowsnormal
fluidflowduringmoderateeffortbrakestops.The
valveonlycontrols(meters)fluidflowduringhigh
effortbrakestops.
FRONTDISCBRAKES
Thecalipersareasinglepistontype.Thecalipers
arefreetoslidelaterally,thisallowscontinuouscom-
pensationforliningwear.
Whenthebrakesareappliedfluidpressureis
exertedagainstthecaliperpiston.Thefluidpressure
isexertedequallyandinalldirections.Thismeans
pressureexertedagainstthecaliperpistonand
withinthecaliperborewillbeequal(Fig.3).
Fluidpressureappliedtothepistonistransmitted
directlytotheinboardbrakeshoe.Thisforcesthe
shoeliningagainsttheinnersurfaceofthedisc
brakerotor.Atthesametime,fluidpressurewithin
thepistonboreforcesthecalipertoslideinwardon
themountingbolts.Thisactionbringstheoutboard
TJ
Fig.3BrakeCaliperOperation
brakeshoeliningintocontactwiththeoutersurface
ofthediscbrakerotor.
Insummary,fluidpressureactingsimultaneously
onbothpistonandcaliper,producesastrongclamp-
ingaction.Whensufficientforceisapplied,friction
willstoptherotorsfromturningandbringthevehi-
cletoastop.
Applicationandreleaseofthebrakepedalgener-
atesonlyaveryslightmovementofthecaliperand
piston.Uponreleaseofthepedal,thecaliperandpis-
tonreturntoarestposition.Thebrakeshoesdonot
retractanappreciabledistancefromtherotor.In
fact,clearanceisusuallyat,orclosetozero.Therea-
sonsforthisaretokeeproaddebrisfromgetting
betweentherotorandliningandinwipingtherotor
surfacecleareachrevolution.
Thecaliperpistonsealcontrolstheamountofpis-
tonextensionneededtocompensatefornormallining
wear.
Duringbrakeapplication,thesealisdeflectedout-
wardbyfluidpressureandpistonmovement(Fig.4).
Whenthebrakes(andfluidpressure)arereleased,
thesealrelaxesandretractsthepiston.
Theamountofpistonretractionisdeterminedby
brakeliningwear.Generallytheamountisjust
enoughtomaintaincontactbetweenthepistonand
inboardbrakeshoe.
REARDRUMBRAKE
Thebrakesystemsusealeadingshoe(primary)
andtrailingshoe(secondary).Themountinghard-
wareissimilarbutnotinterchangeable(Fig.5).

41. TJ
DESCRIPTION ANDOPER
PISTONSEAL
BRAKE
PRESSURE
ON
RIGHTREAR
BRAKEASSEMBLY
SHOE
RETURN
SPRINGS
HOLDDOWN
SPRINGAND
RETAINERS
PR747B
Fig.4LiningWearCompensationByPistonSeal
Whenthebrakepedalisdepresedhydraulicpres-
surepushestherearbrakewheelcylinderpistons
outward.Thewheelcylinderpusrodsthenpushthe
brakeshoesoutwardagainstthebrakedrum.When
thebrakepedalisreleasedreturnspringsattached
tothebrakeshoespulltheshoebacktothereorig-
inalposition.
PARKING BRAKE
Parkingbrakeadjustmentiscontrolledbyacable
tensionermechanism.Thecabletensioner,once
adjustedatthefactory,shouldnotneedfurther
adjustmentundernormalcircumstances.Adjustment
mayberequiredifanewtensioner,orcablesare
installed,ordisconnected.
PARKINGBRAKEOPERATIO
Ahandoperatedleverinthepassengercompart-
mentisthemainapplicationdevice.Thefrontcable
isconnectedbetweenthehandleverandtheten-
sioner.Thetensionerrodisattachedtotheequalizer
TRAILING
DIUSTER
SHOE
EVER
PRING
PARK
BRAKE
STRUT
ADJUSTER
AND
SCREW
ASSEMBLY
LEADING
SHOE
HOLDDOWN
SPRINGAND
RETAINERS
Fig.5BrakeComponents
Fig.6ParkingBrakeComponents
BRAKES 5-5
whichistheconnectingpointfortherearcables(Fig.
6).
Therearcablesareconnectedtotheactuating
leveroneachsecondarybrakeshoe.Theleversare
attachedtothebrakeshoesbyapineitherpressed
into,orweldedtothelever.Aclipisusedtosecure
thepininthebrakeshoe.Thepinallowseachlever
topivotindependentlyofthebrakeshoe.
Toapplytheparkingbrakes,thehandleveris
pulledupward.Thispullstherearbrakeshoeactu-
atingleversforward,bymeanstensionerandcables.
Astheactuatingleverispulledforward,theparking
brakestrut(whichisconnectedtobothshoes),exerts
alinearforceagainsttheprimarybrakeshoe.This
actionpressestheprimaryshoeintocontactwiththe
CYLINDER-
TO-SUPPORT SEAL
19005-13

42. 5-6

BRAKES
DESCRIPTION ANDOPERATION (Continued)
drum.Oncetheprimaryshoecontactsthedrum,
forceisexertedthroughthestrut.Thisforceistrans-
ferredthroughthestruttothesecondarybrakeshoe
causingittopivotintothedrumaswell.
Ageartyperatchetingmechanismisusedtohold
theleverinanappliedposition.Parkingbrake
releaseisaccomplishedbythehandleverrelease
button.
Aparkingbrakeswitchismountedontheparking
brakeleverandisactuatedbymovementofthe
lever.Theswitch,whichisincircuitwiththered
warninglightinthedash,willilluminatethewarn-
inglightwhenevertheparkingbrakesareapplied.
BRAKEHOSESANDLINES
Flexiblerubberhoseisusedat'bothfrontbrakes
andattherearaxlejunctionblock.Doublewalled
steeltubingisusedtoconnectthemastercylinderto
themajorhydraulicbrakingcomponentsandthento
theflexiblerubberhoses.
DIAGNOSISANDTESTING
BASEBRAKESYSTEM
Basebrakecomponentsconsistofthebrakeshoes,
calipers,wheelcylinders,brakedrums,rotors,brake
lines,mastercylinder,booster,andparkingbrake
components.
Brakediagnosisinvolvesdeterminingiftheprob-
lemisrelatedtoamechanical,hydraulic,orvacuum
operatedcomponent.
Thefirstdiagnosisstepisthepreliminarycheck.
PRELIMINARYBRAKECHECK
(1)Checkconditionoftiresandwheels.Damaged
wheelsandworn,damaged,orunderinflatedtires
cancausepull,shudder,vibratioxi,andacondition
similartograb.
(2)Ifcomplaintwasbasedonnoisewhenbraking,
checksuspensioncomponents.Jouncefrontandrear
ofvehicleandlistenfornoisethatmightbecaused
byloose,wornordamagedsuspensionorsteering
components.
(3)Inspectbrakefluidlevelandcondition.Note
thatthefrontdiscbrakereservoirfluidlevelwill
decreaseinproportiontonormalliningwear.Also
notethatbrakefluidtendstodarkenovertime.
Thisisnormalandshouldnotbemistakenfor
contamination.
(a)Iffluidlevelisabnormallylow,lookforevi-
denceofleaksatcalipers,wheelcylinders,brake
lines,andmastercylinder.
(b)Iffluidappearscontaminated,drainouta
sample.Systemwillhavetobeflushediffluidis
separatedintolayers,orcontainsasubstance
otherthanbrakefluid.Thesystemsealsandcups
TJ
willalsohavetobereplacedafterflushing.Use
cleanbrakefluidtoflushthesystem.
(4)Checkparkingbrakeoperation.Verifyfree
movementandfullreleaseofcablesandpedal.Also
noteifvehiclewasbeingoperatedwithparking
brakepartiallyapplied.
(5)Checkbrakepedaloperation.Verifythatpedal
doesnotbindandhasadequatefreeplay.Ifpedal
lacksfreeplay,checkpedalandpowerboosterfor
beinglooseorforbindcondition.Donotroadtest
untilconditioniscorrected.
(6)IfcomponentscheckedappearOK,roadtest
thevehicle.
ROADTESTING
(1)Ifcomplaintinvolvedlowbrakepedal,pump
pedalandnoteifitcomesbackuptonormalheight.
(2)Checkbrakepedalresponsewithtransmission
inNeutralandenginerunning.Pedalshouldremain
firmunderconstantfootpressure.
(3)Duringroadtest,makenormalandfirmbrake
stopsin25-40mphrange.Notefaultybrakeopera-
tionsuchaslowpedal,hardpedal,fade,pedalpulsa-
tion,pull,grab,drag,noise,etc.
PEDALFALLSAWAY
Abrakepedalthatfallsawayundersteadyfoot
pressureisgenerallytheresultofasystemleak.The
leakpointcouldbeatabrakeline,fitting,hose,or
caliper/wheelcylinder.Internalleakageinthemaster
cylindercausedbywornordamagedpistoncups,
mayalsobetheproblemcause.
Ifleakageissevere,fluidwillbeevidentator
aroundtheleakingcomponent.However,internal
leakageinthemastercylindermaynotbephysically
evident.
LOWPEDAL
Ifalowpedalisexperienced,pumpthepedalsev-
eraltimes.Ifthepedalcomesbackup,wornlining,
rotors,ordrumsarethemostlikelycauses.
SPONGYPEDAL
Aspongypedalismostoftencausedbyairinthe
system.However,thinbrakedrumsorsubstandard
brakelinesandhosescanalsocauseaspongypedal.
Thepropercourseofactionistobleedthesystem,or
replacethindrumsandsuspectqualitybrakelines
andhoses.
HARDPEDALORHIGHPEDALEFFORT
Ahardpedalorhighpedaleffortmaybedueto
liningthatiswatersoaked,contaminated,glazed,or
badlyworn.Thepowerboosterorcheckvalvecould
alsobefaulty.

43. TJ
DIAGNOSIS ANDTESTING I(Continued)
PEDALPULSATION
Pedalpulsationiscausedbycomponentsthatare
loose,orbeyondtolerancelimits.
Theprimarycauseofpulsationarediscbrake
rotorswithexcessivelateralrunotorthicknessvari-
ation,oroutofroundbrakedrum.Othercausesare
loosewheelbearingsorcalipersndworn,damaged
tires.
NOTE:Somepedalpulsationnaybefeltduring
ABSactivation.
BRAKEDRAG
Brakedragoccurswhentheliningisinconstant
contactwiththerotorordrum.Dragcanoccuratone
wheel,allwheels,frontsonly,orearsonly.
Dragisaproductofincomplete

rakeshoerelease.
Dragcanbeminororsevereenoghtooverheatthe
linings,rotorsanddrums.
Minordragwillusuallycauselightsurfacechar-
ringofthelining.Itcanalsogeneratehardspotsin
rotorsanddrumsfromtheoverheat-cooldownpro-
cess.Inmostcases,therotors,rums,wheelsand
tiresarequitewarmtothetouchafterthevehicleis
stopped.
Severedragcancharthebrakeliningalltheway
through.Itcanalsodistortanscorerotorsand
drumstothepointofreplacemen.Thewheels,tires
andbrakecomponentswillbeextremelyhot.In
severecases,theliningmaygeneratesmokeasit
charsfromoverheating.
Possiblecausesforbrakedragconditionare:
"Seizedorimproperlyadjustedparkingbrake
cables.
"Loose/wornwheelbearing.
"Seizedcaliperorwheelcylinerpiston.
"Caliperbindingoncorrodedbushingsorrusted
slidesurfaces.
"Loosecalipermountingbracket.
"Drumbrakeshoesbindingonworn/damaged
supportplates.
"Misassembledcomponents.
Ifbrakedragoccursatallwheels,theproblem
mayberelatedtoablockedmasercylinderreturn
port,orfaultypowerbooster(bins-doesnotrelease).
BRAKEFADE
Brakefadeisusuallyaprod)ctofoverheating
causedbybrakedrag.However,brakeoverheating
andresultingfadecanalsobecausedbyridingthe
brakepedal,makingrepeatedhighdecelerationstops
inashorttimespan,orconstantbrakingonsteep
mountainroads.RefertotheBrakeDraginformation
inthissectionforcauses.
BRAKEPULL
Possiblecausesforfrontbrakepullconditionare:
Contaminatedlininginonecaliper.
Seizedcaliperpiston.
Bindingcaliper.
Loosecaliper.
Rustyadapter/caliperslidesurfaces.
"Improperbrakeshoes.
"Damagedrotor.
Aworn,damagedwheelbearingorsuspension
componentarefurthercausesofpull.Adamaged
fronttire(bruised,plyseparation)canalsocause
pull.
Acommonandfrequentlymisdiagnosedpullcondi-
tioniswheredirectionofpullchangesafterafew
stops.Thecauseisacombinationofbrakedragfol-
lowedbyfadeatoneofthebrakeunits.
Asthedraggingbrakeoverheats,efficiencyisso
reducedthatfadeoccurs.Sincetheoppositebrake
unitisstillfunctioningnormally,itsbrakingeffectis
magnified.Thiscausespulltoswitchdirectionin
favorofthenormallyfunctioningbrakeunit.
Anadditionalpointwhendiagnosingachangein
pullconditionconcernsbrakecooldown.Remember
thatpullwillreturntotheoriginaldirection,ifthe
draggingbrakeunitisallowedtocooldown(andis
notseriouslydamaged).
BRAKES

5-7
REARBRAKEGRABORPULL
Reargraborpullisusuallycausedbyimproperly
adjustedorseizedparkingbrakecables,contami-
natedlining,bentorbindingshoesandsupport
plates,orimproperlyassembledcomponents.Thisis
particularlytruewhenonlyonerearwheelis
involved.However,whenbothrearwheelsare
affected,themastercylinder,proportioningvalve,or
RWALvalvecouldbeatfault.
BRAKESDONOTHOLDAFTERDRIVINGTHROUGHDEEP
WATERPUDDLES
Thisconditionisgenerallycausedbywatersoaked
lining.Iftheliningisonlywet,itcanbedriedby
drivingwiththebrakesverylightlyappliedfora
mileortwo.However,iftheliningisbothsoakedand
dirtcontaminated,cleaningand/orreplacementwill
benecessary.
BRAKESQUEAK/SQUEAL
Brakesqueakorsquealmaybeduetoliningsthat
arewetorcontaminatedwithbrakefluid,grease,or
oil.Glazedliningsandrotorswithhardspotscan
alsocontributetosqueak.Dirtandforeignmaterial
embeddedinthebrakeliningwillalsocausesqueak/
squeal.
Averyloudsqueakorsquealisfrequentlyasignof
severelywornbrakelining.Ifthelininghasworn
throughtothebrakeshoesinspots,metal-to-metal

44. 5-8 BRAKES
DIAGNOSIS ANDTESTING (Continued)
contactoccurs.Iftheconditionisallowedtocontinue,
rotorsanddrumscanbecomesoscoredthatreplace-
mentisnecessary.
BRAKECHATTER
Brakechatterisusuallycausedbylooseorworn
components,orglazed/burntlining.Rotorswithhard
spotscanalsocontributetochatter.Additionalcauses
ofchatterareout-of-tolerancerotors,brakeliningnot
securelyattachedtotheshoes,loosewheelbearings
andcontaminatedbrakelining.
THUMP/CLUNKNOISE
Thumpingorclunknoisesduringbrakingarefre-
quentlynotcausedbybrakecomponents.Inmany
cases,suchnoisesarecausedbylooseordamaged
steering,suspension,orenginecomponents.However,
calipersthatbindontheslidesurfacescangenerate
athumporclunknoise.Inaddition,wornout,
improperlyadjusted,orimproperlyassembledrear
brakeshoescanalsoproduceathumpnoise.
BRAKELININGCONTAMINATION
Brakeliningcontaminationismostlyaproductof
leakingcalipersorwheelcylinders,wornseals,driv-
ingthroughdeepwaterpuddles,orliningthathas
becomecoveredwithgreaseand,gritduringrepair.
Contaminatedliningshouldbereplacedtoavoidfur-
therbrakeproblems.
WHEELANDTIREPROBLEMS
Someconditionsattributedtobrakecomponents
mayactuallybecausedbyawheelortireproblem.
Adamagedwheelcancauseshudder,vibrationand
pull.Awornordamagedtirecanalsocausepull.
Severelyworntireswithverylittletreadleftcan
produceagrab-likeconditionasthetirelosesand
recoverstraction.Flat-spottedtirescancausevibra-
tionandgenerateshudderduringbrakeoperation.A
tirewithinternaldamagesuchasaseverebruise,
cut,orplyseparationcancausepullandvibration.
STOPLAMPSWITCH
Stoplampswitchoperationcanbetestedwithan
ohmmeter.Theohmmeterisusedtocheckcontinuity
betweenthepinterminalsatdifferentplungerposi-
tions(Fig.7).
NOTE:Theswitchwireharnessmustbediscon-
nectedbeforetestingswitchcontinuity.
SWITCH CIRCUIT IDENTIFICATION
"Terminals1and2areforbrokesensorcircuit.
"Terminals5and6areforthstoplampcircuit.
"Terminals3and4arenotu:ed.
TERMINAL
PINS
TJ
J9405-88
Fig.7StopLampSwitchTerminalIdentification
SWITCH CONTINUITY TEST
(1)Checkcontinuitybetweenterminalpins5and
6asfollows:
(a)Pullplungerallthewayouttofullyextended
position.
(b)Attachtestleadstopins5and6andnote
ohmmeterreading.
(c)Ifcontinuityexists,proceedtonexttest.
Replaceswitchifmeterindicateslackofcontinuity
(shortedoropen).
(2)Checkcontinuitybetweenterminalpins1and
2asfollows:
(a)Pushswitchplungerinwardtofully
retractedposition.
(b)Attachtestleadstopins1and2andnote
ohmmeterreading.
(c)Ifcontinuityexists,switchisOK.Replace
switchifmeterindicateslackofcontinuity(switch
isopen).
REDBRAKEWARNING LAMP
Theredbrakewarninglightwillilluminateunder
thefollowingconditions:
"2-3secondsatstart-upaspartofnormalbulb
check.
"Whenparkingbrakesareapplied.
"Lowbrakepedalcausedbyleakinfront/rear
brakehydrauliccircuit.
Iftheredlightremainsonafterstart-up,firstver-
ifythattheparkingbrakesarefullyreleased.Then
checkpedalactionandfluidlevel.Aredlightplus
lowpedalindicatesthepressuredifferentialswitch
andvalvehavebeenactuatedduetoasystemleak.
OnmodelswithABSbrakes,theamberwarning
lightonlyilluminateswhenanABSmalfunctionhas
occurred.TheABSlightoperatesindependentlyof
theredwarninglight.
ForadditioninformationrefertoGroup8W

45. TJ
DIAGNOSIS ANDTESTIN
MASTERCYLINDER/POWER BO
(1)Startengineandcheckb
connections.Ahissingnoisefind
Correctanyvacuumleakbefore
(2)Stopengineandshifttra
tral.
(3)Pumpbrakepedaluntilal
boosterisdepleted.
(4)Pressandholdbrakepe
pressure.Thepedalshouldhol
fallsawaymastercylinderisf
age).
(5)Startengineandnotepe
fallsawayslightlyunderlight
holdsfirm.Ifnopedalactioni
booster,vacuumsupply,orvac
faulty.ProceedtothePOWER
TEST.
(6)IfthePOWERBOOSTE
passes,rebuildboostervacuum
Releasebrakepedal.Increasee
rpm,closethethrottleandimm
ignitiontostopengine.
(7)Waitaminimumof90se
actionagain.Boostershouldprovidetwoormorevac-
uumassistedpedalapplications.]Ifvacuumassistis
notprovided,boosterisfaulty.

I
STER
ostervacuumhose
catesvacuumleak.
roceeding.
smissionintoNeu-
alunderlightfoot
firm,ifthepedal
ulty(internalleak-
alactionitshould
footpressurethen
discernible,power
umcheckvalveis
OOSTERVACUUM
VACUUM TEST
reserveasfollows:
ginespeedto1500
diatelystopturnoff
POWERBOOSTER VACUUM EST
(1)Connectvacuumgaugetoboostercheckvalve
withshortlengthofhoseandT-fitting(Fig.8).
(2)Startandrunengineatcrbidlespeedforone
minute.
(3)Observethevacuumsupply.Ifvacuumsupply
isnotadequate,repairvacuumsupply.
(4)Clamphoseshutbetween,'vacuumsourceand
checkvalve.
(5)Stopengineandobservevcuumgauge.
(6)Ifvacuumdropsmoreth,~,InoneinchHG(33
millibars)within15seconds,boosterdiaphragmor
checkvalveisfaulty.
POWERBOOSTER CHECK"LVETEST
(1)Disconnectvacuumhosefromcheckvalve.
(2)Removecheckvalveandvalvesealfrom
booster.
(3)Useahandoperatedvacuumpumpfortest.
(4)Apply15-20inchesvacuumatlargeendof
checkvalve(Fig.9).
(5)Vacuumshouldholdsteady.Ifgaugeonpump
indicatesvacuumloss,check'valveisfaultyand
shouldbereplaced.
VACUUM
GAUGE
SHORT
CONNECTING CHECK
HOSE VALVE
BOOSTER
CHECKVALVE

APPLYTEST
VACUUMHERE
VALVE
SEAL
COMBINATION VALVE
BRAKES 5-9
INTAKE
MANIFOLD
Fig.8TypicalBoosterVacuumTestConnections
Fig.9VacuumCheckValveAndSeal
J9oos-81
8031e866
MeteringValve
Meteringvalveoperationcanbecheckedvisually
andwiththeaidofahelper.Observethemetering
valvestemwhileahelperappliesandreleasesthe
brakes.Ifthevalveisoperatingcorrectly,thestem
willextendslightlywhenthebrakesareappliedand
retractwhenthebrakesarereleased.Ifthevalveis
faulty,replacetheentirecombinationvalveasan
assembly.
PressureDifferentialSwitch
(1)Havehelpersitindriversseattoapplybrake
pedalandobserveredbrakewarninglight.
(2)Raisevehicleonhoist.

46. 5
1
-10 BRAKES
DIAGNOSIS ANDTESTING (Continued)
(3)Connectbleedhosetoarearwheelcylinder
andimmersehoseendincontainerpartiallyfilled
withbrakefluid.
(4)Havehelperpressandholdbrakepedaltofloor
andobservewarninglight.
(a)Ifwarninglightilluminates,switchisoperat-
ingcorrectly.
(b)Iflightfailstoilluminate,checkcircuitfuse,
bulb,andwiring.Theparkingbrakeswitchcanbe
usedtoaidinidentifyingwhetherornotthebrake
lightbulbandfuseisfunctional.Repairorreplace
partsasnecessaryandtestdifferentialpressure
switchoperationagain.
(5)Ifwarninglightstilldoesnotilluminate,
switchisfaulty.Replacecombinationvalveassembly,
bleedbrakesystemandverifyproperswitchand
valveoperation.
DISCBRAKEROTOR
Therotorbrakingsurfacesshouldnotberefinished
unlessnecessary.
Lightsurfacerustandscalecanberemovedwitha
latheequippedwithdualsandingdiscs.Therotor
surfacescanberestoredbymachininginadiscbrake
latheifsurfacescoringandweararelight.
Replacetherotorunderthefollowingconditions:
"SeverelyScored
"Tapered
"HardSpots
"Cracked
"BelowMinimumThickness
ROTORMINIMUMTHICKNESS
Measurerotorthicknessatthecenterofthebrake
shoecontactsurface.Replacetherotorifwornbelow
minimumthickness,orifmachiningwouldreduce
thicknessbelowtheallowableminimum.
Rotorminimumthicknessisusuallyspecifiedon
therotorhub.Thespecificationiseitherstampedor
castintothehubsurface.
ROTORRUNOUT
Checkrotorlateralrunoutwithdialindicator
C-3339(Fig.10).Excessivelateralrunoutwillcause
brakepedalpulsationandrapid,unevenwearofthe
brakeshoes.Positionthedialindicatorplunger
approximately25.4mm(1in.)inwardfromtherotor
edge.
NOTE:Besurewheelbearinghaszeroendplay
beforecheckingrotorrunout.
Maximumallowablerotorrunoutis0.102mm
(0.004in.).
DIAL
INDICATOR
J8905-68
Fig.10CheckingRotorRunoutAndThickness
Variation
ROTORTHICKNESSVARIATION
Variationsinrotorthicknesswillcausepedalpul-
sation,noiseandshudder.
Measurerotorthicknessat6-to-12pointsaround
therotorface(Fig.11).
Positionthemicrometerapproximately25.4mm(1
in.)fromtherotoroutercircumferenceforeachmea-
surement.
Thicknessshouldnotvarybymorethan0.013mm
(0.0005in.)frompoint-to-pointontherotor.Machine
orreplacetherotorifnecessary.
TAKEMINIMUM
OF6MEASUREMENTS
AROUNDROTOR
Fig.11MeasuringRotorThickness
TJ
BRAKEDRUM
Themaximumallowablediameterofthedrum
brakingsurfaceisstampedorcastintothedrum
outeredge.Generally,adrumcanbemachinedtoa
maximumof1.52mm(0.060in.)oversize.Always

47. TJ
DIAGNOSIS ANDTESTIN
replacethedrumifmachining
diametertoexceedthesizeli
drum.
PARKINGBRAKE
(Continued)
wouldcausedrum
itindicatedonthe
BRAKEDRUMRUNOUT
Measuredrumdiameterandr
rategauge.Themostaccurate
mentinvolvesmountingthedr
andcheckingvariationandrun
cator.
Variationsindrumdiametershouldnotexceed
0.076mm(0.003in.).Drumrunotshouldnotexceed
0.20mm(0.008in.)outofround.Machinethedrum
ifrunoutorvariationexceedthesevalues.Replace
thedrumifmachiningcausesthedrumtoexceedthe
maximumallowablediameter.
noutwithanaccu-
ethodofmeasure-
minabrakelathe
utwithadialindi-
NOTE:Parkingbrakeadjusmetiscontrolledbya
cabletensioner.Oncethetensinerisadjustedat
thefactory,itshouldnotrequiefurtherattention.
However,therearetwoinstanceswhenadjustment
willberequired.Thefirstiswhnanewtensioner,
orcableshavebeeninstalled.ndthesecond,is
whenthetensionerandcablesredisconnectedfor
accesstootherbrakecomponets.
Theparkingbrakeswitchisinl,circuitwiththered
warninglampinthedash.Thewitchwillcausethe
lamptoilluminateonlywhentheparkingbrakesare
applied.Ifthelampremainsonafterparkingbrake
release,theswitchorwiresareIlfaulty,orcableten-
sioneradjustmentisincorrect.
Inmostcases,theactualcauseofanimproperly
functioningparkingbrake(tooloose/tootight/won't
hold),canbetracedtoaparkingbrakecomponent.
Theleadingcauseofimproper'parkingbrakeoper-
ation,isexcessiveclearancebetweentheparking
brakeshoesandtheshoebrakingsurface.Excessive
clearanceisaresultofliningand/ordrumwear,
drumsurfacemachinedoversize,orinoperative
adjustercomponents.
Excessiveparkingbrakelevertravel(sometimes
describedasalooseleverortoloosecondition),is
theresultofwornbrakeshoes,mproperbrakeshoe
adjustment,orimproperlyassembledbrakeparts.
Aconditionwheretheparkingbrakesdonothold,
willmostprobablybeduetoa'wwheelbrakecompo-
nent.
Itemstolookforwhendiagnosingaparkingbrake
problem,are:
"Rearbrakeshoewear.
"Drumsurfacemachinedoversize.
"Frontcablenotsecuredtolever.
"Rearcablenotattachedtolever.
"Rearcableseized.
BRAKES 5-11
"Brakeshoesreversed.
"Parkingbrakestrutnotseatedinshoes.
"Parkingbrakelevernotseated.
"Parkingbrakeleverbind.
"Adjusterscrewsseized.
"Adjusterscrewsreversed.
Parkingbrakeadjustmentandpartsreplacement
proceduresaredescribedintheParkingBrakesec-
tion.
BRAKELINEANDHOSES
Flexiblerubberhoseisusedatbothfrontbrakes
andattherearaxlejunctionblock.Inspectthehoses
wheneverthebrakesystemisserviced,atevery
engineoilchange,orwheneverthevehicleisinfor
service.
Inspectthehosesforsurfacecracking,scuffing,or
wornspots.Replaceanybrakehoseimmediatelyif
thefabriccasingofthehoseisexposedduetocracks
orabrasions.
Alsocheckbrakehoseinstallation.Faultyinstalla-
tioncanresultinkinked,twistedhoses,orcontact
withthewheelsandtiresorotherchassiscompo-
nents.Alloftheseconditioncanleadtoscuffing,
crackingandeventualfailure.
Thesteelbrakelinesshouldbeinspectedperiodi-
callyforevidenceofcorrosion,twists,kinks,leaks,or
otherdamage.Heavilycorrodedlineswilleventually
rustthroughcausingleaks.Inanycase,corrodedor
damagedbrakelinesshouldbereplaced.
Factoryreplacementbrakelinesandhosesarerec-
ommendedtoensurequality,correctlengthandsupe-
riorfatiguelife.Careshouldbetakentomakesure
thatbrakelineandhosematingsurfacesareclean
andfreefromnicksandburrs.Alsorememberthat
rightandleftbrakehosesarenotinterchangeable.
Usenewcoppersealwashersatallcaliperconnec-
tions.Besurebrakelineconnectionsareproperly
made(notcrossthreaded)andtightenedtorecom-
mendedtorque.
BRAKEFLUIDCONTAMINATION
Indicationsoffluidcontaminationareswollenor
deterioratedrubberparts.
Swollenrubberpartsindicatethepresenceof
petroleuminthebrakefluid.
Totestforcontamination,putasmallamountof
drainedbrakefluidinclearglassjar.Iffluidsepa-
ratesintolayers,thereismineraloilorotherfluid
contaminationofthebrakefluid.
Ifbrakefluidiscontaminated,drainandthor-
oughlyflushsystem.Replacemastercylinder,propor-
tioningvalve,caliperseals,wheelcylinderseals,
AntilockBrakeshydraulicunitandallhydraulic
fluidhoses.

48. 5-12

BRAKES=
SERVICEPROCEDURES
BRAKEFLUIDLEVEL
Alwayscleanthemastercylinderreservoirandcap
beforeaddingfluid.Thiswillpreventdirtfromfall-
inginthereservoirandcontaminatingthebrake
fluid.
ThereservoirhasaADDandaFULLmarkonthe
side(Fig.12)filltotheFULLmark.
Fig.12MasterCylinderFluidLevel
MASTERCYLINDER
Anewmastercylindershouldbebledbeforeinstal-
lationonthevehicle.Requiredbleedingtoolsinclude
bleedtubesandawooddoweltostrokethepistons.
Bleedtubescanbefabricatedfrombrakeline.
BLEEDINGPROCEDURE
(1)Mountmastercylinderinvise.
(2)Attachbleedtubestocylinderoutletports.
Thenpositioneachtubeendinmatchingreservoir
fluidcompartment(Fig.13).
NOTE:Ifmastercylindershasonereservoiropen-
ing,positionbothoutletbleedtubesintothesingle
reservoiropening.
(3)Fillreservoirwithfreshbrakefluid.
(4)Presscylinderpistonsinwardwithwooddowel.
Thenreleasepistonsandallowtheretoreturnunder
springpressure.Continuebleedingoperationsuntil
airbubblesarenolongervisibleinfluid.
BRAKEBLEEDING
UseMoparbrakefluid,oranequivalentquality
fluidmeetingSAEJ1703-FandDOT3standards
only.Usefresh,cleanfluidfromasealedcontainerat
alltimes.
Donotpumpthe
bleeding.Airinthe
smallbubblesthat
brakepedalatanytimewhile
systemwillbecompressedinto
aredistributedthroughoutthe
TJ
BLEEDING
RH232
TUBES

HOUSING

DOWEL
MASTERCYLINDER
Fig.13MasterCylinderBleeding
hydraulic.system.Thiswillmakeadditionalbleeding
operationsnecessary.
Donotallowthemastercylindertorunoutoffluid
duringbleedoperations.Anemptycylinderwillallow
additionalairtobedrawnintothesystem.Checkthe
cylinderfluidlevelfrequentlyandaddfluidas
needed.
TheBrakesshouldbebledinsequence.Firstthe
rightrearwheelthentheleftrearwheel.Thenmove
tothefrontbrakesandbleedtherightfrontwheel
thentheleftfrontwheel.
MANUALBLEEDING
(1)Removereservoirfillercapsandfillreservoir
withMopar,orequivalentqualityDOT3brakefluid.
(2)Ifcalipers,orwheelcylinderswereoverhauled,
openallcaliperandwheelcylinderbleedscrews.
Thencloseeachbleedscrewasfluidstartstodrip
fromit.Topoffmastercylinderreservoironcemore
beforeproceeding.
(3)Attachoneendofbleedhosetobleedscrew
andinsertoppositeendinglasscontainerpartially
filledwithbrakefluid(Fig.14).Besureendofbleed
hoseisimmersedinfluid.
(4)Openupbleeder,thenhaveahelperpress
downthebrakepedal.Oncethepedalisdownclose
thebleeder.Repeatbleedinguntilfluidstreamis
clearandfreeofbubbles.Thenmovetothenext
wheel.
DISCROTORMACHINING
Rotorbrakingsurfacescanbesandedormachining
inadiscbrakelathe.
Thelathemustmachinebothsidesoftherotor
simultaneouslywithdual(two)cutterheads(Fig.
15).Equipmentcapableofmachiningonlyonesideat
atimewillproduceataperedrotor.

49. TJ
SERVICE PROCEDURES (Continued)
FLUID
CONTAINER
PARTIALLY
FILLEDWITH
FLUID
BRAKEDRUMMACHINING
J8905-18
Fig.14TypicalFluidContainerAndBleedHose
Setup
Thelatheshouldalsobeequippedwithagrinder
attachmentordualsandingdiscs~orfinalcleanupor
lightrefinishing(Fig.15).
Iftherotorsurfacesonlyneedminorcleanupof
rust,scale,orminorscoring,useabrasivediscsto
cleanuptherotorsurfaces.However,whenarotoris
scoredorworn,machiningwithcuttingtoolswillbe
required.
CAUTION:Donotmachinetherotorifitwillcause
therotortofallbelowminimumallowablethick-
ness.
Thebrakedrumscanbemachiedonadrumlathe
whennecessary.Initialmachiningcutsshouldbelim-
itedto0.12-0.20mm(0.005-0.08in.)atatimeas
heavierfeedratescanproducetaperandsurface
variation.Finalfinishcutsof0.025to0.038mm
(0.001to0.0015in.)arerecommendedandwillgen-
erallyprovidethebestsurfacefinish.
Besurethedrumissecurelym~Ountedinthelathe
beforemachiningoperations.Adamperstrapshould
alwaysbeusedaroundthedrumItoreducevibration
andavoidchattermarks.
Themaximumallowabledia~eterofthedrum
brakingsurfaceisstampedorcastintothedrum
outeredge.Alwaysreplacethedrumifmachining
wouldcausedrumdiametertoexceedthesizelimit
indicatedonthedrum.
Fig.15RotorRefinishing
BRAKES 5-13
J8905-70
BRAKELINE
Moparpreformedmetalbrakelineisrecommended
andpreferredforallrepairs.However,double-wall
steellinecanbeusedforemergencyrepairwhenfac-
toryreplacementpartsarenotreadilyavailable.
Special,heavydutytubebendingandflaring
equipmentisrequiredtopreparedoublewallbrake
line.Specialbendingtoolsareneededtoavoidkink-
ingortwistingmetalbrakeline.Inaddition,special

50. 5-14 BRAKES
SERVICEPROCEDURES (Continued)
flaringtoolsareneededtoprovidetheinverted-type,
doubleflarerequiredonmetalbrakelines.
FLARINGPROCEDURE
(1)CutoffdamagedtubewithTubingCutter.
(2)Reamcutedgesoftubingtoensureproper
flare.
(3)Installreplacementtubenutonsectionoftube
toberepaired.
(4)Inserttubeinflaringtool.Centertubeinarea
betweenverticalposts.
(5)Placegaugeformovertheendofthetube.
(6)Pushtubingthroughflaringtooljawsuntil
tubecontactsrecessednotchingaugethatmatches
tubediameter.
(7)Squeezeflaringtooljawstolocktubingin
place.
(8)Insertplugongaugeinthetube.Thenswing
compressiondiscovergaugeandcentertaperedflar-
ingscrewinrecessofcompressiondisc(Fig.16).
(9)Tightentoolhandleuntilpluggaugeisseated
onjawsofflaringtool.Thiswillstarttheinverted
flare.
(10)Removethepluggaugeandcompletethe
invertedflare.
(11)Removetheflaringtoolsandverifythatthe
invertedflareiscorrect.
Fig.16InvertedFlareTools
RH222
REMOVAL ANDINSTALLATION
STOPLAMPSWITCH
REMOVAL
(1)Removesteeringcolumncoverandlowertrim
panelforswitchaccess(ifnecessary).
(2)Pressbrakepedaldownwardtofullyapplied
position.
(3)Rotateswitchapproximately30°incounter-
clockwisedirectiontounlockswitchretainer.Then
pullswitchrearwardandoutofbracket.
(4)Disconnectswitchwireharnessandremove
switchfromvehicle(Fig.17).
BRAKEPEDAL
Fig.17StopLampSwitch
TERMINALS
J9405-153
TJ
INSTALLATION
(1)Pullswitchplungerallthewayouttofully
extendedposition.
(2)Connectharnesswirestoswitch.
(3)Pressandholdbrakepedalinappliedposition.
(4)Installswitchasfollows:Aligntabonswitch
withnotchinswitchbracket.Theninsertswitchin
bracketandturnitclockwiseabout30°tolockitin
place.
(5)Releasebrakepedal,thenpullpedalfullyrear-
ward.Pedalwillsetplungertocorrectpositionas
pedalpushesplungerintoswitchbody.Switchwill
makerachetingsoundasitselfadjusts.
REMOVAL
(1)Removenegativebatterycable.
(2)Removebrakelampswitch.
(3)RemoveABScontrollerifequipped.
(4)Removeretainerclipsecuringboosterpushrod
topedal(Fig.18)andclutchrodretainerclipif
equipped.

51. TJ
REMOVAL ANDINSTALLATION (Continued)
(5)Removeboltsfrombrakepedalsupportand
boostermountingnuts.Remove

ountingstudplate
nutsorclutchcylindermountingnutsifequipped.
(6)Slidbrakebooster/mastercylinderassembly
forward.
(7)Removemountingstudplateorslidclutchcyl-
inderforwardifequipped.
(8)Tiltthepedalsupportdowntogainshaftclear-
ance.
(9)RemovepedalshaftC-clipfrompassengerside
oftheshaft.
(10)Slidethepedalshafttowardthedriversside
andremovetheremainingC-clip
(11)Slidtheshaftoutofthepedalbracketand
removethepedal.
(12)Removepedalbushingsliftheyaretobe
replaced.
Fig.18PushRodAttachment
INSTALLATION
(1)Installnewbushingsinpedal.Lubricatebush-
ingsandshaftwithmulti-purposegrease.
(2)Positionpedalinbracketandinstallshaft.
(3)InstallnewpivotpinC-clip.
(4)Positionpedalsupportand!installsupportbolts
andtightento28N-m(21ft.lbs.).
(5)Slidthebooster/mastercylinderassemblyinto
place,installmountingnutsandtightento37N-m
(27ft.lbs.).
(6)Installstudplateorclutch'cylinderifequipped
andtightenmountingnutto28',,11V-m(21ft.lbs.).
Installretainerclipsecuringboosterpushrodto
pedal(Fig.18)andclutchrodretainerclipif
equipped.
(7)InstallABScontrollerifequipped.
(8)Installandconnectstoplampswitch.
(9)Installnegativebatterycable.
COMBINATIONVALVE
REMOVAL
(1)Removebrakelinesthatconnectmastercylin-
dertocombinationvalve(Fig.19).
(2)Disconnectbrakelinesthatconnectcombina-
tionvalvetofrontandrearbrakes.
(3)Disconnectwirefromcombinationvalveswitch
terminal.Becarefulwhenseparatingwireconnector
aslocktabsareeasilydamagedifnotfullydisen-
gaged.
(4)Removenutsattachingcombinationvalve
brackettoboosterstudsandremovevalvebracketoff
boosterstuds(Fig.20).
COMBINATION
VALVE
BRAKES

5-15
Fig.19CombinationValve/MasterCylinder
MASTERCYLINDER
Fig.20CombinationValveBracket
MASTER
CYLINDER
80al8d4d
COMBINATION
VALVEBRACKET

8Oal8d4f
INSTALLATION
(1)Positionvalvebracketonboosterstudsand
tightenbracketattachingnutsto24N-m(18ft.lbs.).
(2)Alignandstartbrakelinefittingsincombina-
tionvalveandmastercylinderbyhandtoavoidcross
threading.

52. 5-16 BRAKES
REMOVALANDINSTALLATION(Continued)
(3)Tightenbrakelinefittingsatcombinationvalve
to21N-m(15ft.lbs.).
(4)Tightenbrakelinefittingsatmastercylinder
to15N-m(11ft.lbs.).
(5)Connectwiretodifferentialpressureswitchin
combinationvalve.
(6)Bleedbasebrakesystem.
MASTERCYLINDER
REMOVAL
(1)Removeevaporativecanister,refertoGroup25
Emissionsforserviceprocedure.
(2)Disconnectbrakelinestomastercylinderand
combinationvalve.
(3)Removecombinationvalvemountingnutsand
removevalve.
(4)Removemastercylindermountingnutsand
removemastercylinder.
(5)Removecylindercoveranddrainfluid.
(6)Ifmastercylinderreservoirrequiresservice,
refertoReservoirReplacementProcedure.
INSTALLATION
NOTE:Bleednewmastercylinderonbenchbefore
installation,refertoServiceProcedures.
(1)Removeprotectivesleevefromprimarypiston
shankonnewmastercylinder.
(2)Checkconditionofsealatrearofcylinderbody.
Repositionsealifdislodged.Replacesealifcut,or
torn.
(3)Installmastercylinderontobrakebooster
studsandtightenmountingnutsto24N-m(18ft.
lbs.).
(4)Installcombinationvalveontobrakebooster
studsandtightenmountingnutsto24N-m(18ft.
lbs.).
(5)Installbrakelinestomastercylinderandcom-
binationvalvebyhandtoavoidcrossthreading.
(6)Tightenmastercylinderbrakelinesto15N-m
(11ft.lbs.).
(7)Tightencombinationvalvebrakelinesto21
N-m(15ft.lbs.).
(8)Installevaporativecanister,refertoGroup25
Emissionsforserviceprocedure.
(9)Bleedbasebrakesystem.
POWERBRAKEBOOSTER
REMOVAL
(1)Removecombinationvalveandmastercylinder.
(2)Disconnectvacuumhosefromboostercheck
valve.
(3)Removeretainingclipthatsecuresbooster
pushrodtobrakepedal(Fig.21).
(4)Removenutsattachingboostertocowlpanel
(Fig.22).
(5)Inenginecompartment,slideboosterstudsout
ofcowlpanel,andremoveboosterfromenginecom-
partment.
(6)Removedashsealfrombooster.
Fig.21PushRod&Clip
Fig.22BoosterMountingNuts
TJ
INSTALLATION
(1)Installdashsealonbooster.
(2)Alignandpositionboosterondashpanel.
(3)Inpassengercompartment,installnutsthat
attachboostertodashpanel.Tightennutsjust
enoughtoholdboosterinplace.
(4)Slideboosterpushrodontobrakepedal.Then
securepushrodtopedalpinwithretainingclip.
(5)Tightenboostermountingnutsto37N-m(27
ft.lbs.).
(6)Connectvacuumhosetoboostercheckvalve.
(7)Installmastercylinderandcombinationvalve.
(8)Topoffmastercylinderfluidlevelandbleed
basebrakes.

53. TJ
REMOVAL ANDINSTALLATION (Continued)
DISCBRAKECALIPER
REMOVAL
(1)Raisevehicleand
assemblies.
(2)Removeanddiscard
(Fig.23).
Fig.23BrakeHoseAlndBolt
FITTING
WASHERS
(3)Removecalipermountingbolts.
(4)Rotatecaliperrearwardwithprytoolifneces-
sary.Thenrotatecaliperandbrakeshoesoffmount-
ingledges.
(5)Removecaliperfromvehicl.
INSTALLATION
(1)Installbrakeshoesincaliper.
(2)Connectbrakehosetocaliperbutdonot
tightenfittingboltcompletelyatIthistime.Besure
tousenewgasketsonbolttoavoidleaks
(3)Installcaliper.Positionmountingnotchesat
lowerendofbrakeshoesonbottommountingledge.
ThenrotatecaliperoverrotorIndseatnotchesat
upperendofshoesonmountingledge.
(4)CoatcalipermountingboltswithGE661or
Dow111siliconegrease.Then,installandtighten
boltsto15N-m(11ft.lbs.).
CAUTION:Ifnewcaliperboltslorebeinginstalled,
oriftheoriginalreasonforrepairwasadrag/pull
condition,checkcaliperboltlenthbeforeproceed-
ing.Iftheboltshaveashank~engthgreaterthan
67.6mm(2.66in.),theymaycontacttheinboard
brakeshoecausingapartialapplycondition.Refer
toFigure14fortherequiredcalliperboltlength.
(5)Positionfrontbrakehoseclearofallchassis
componentsandtightencaliperfittingboltto31N-m
(23ft.lbs.).
CAUTION:

Besurethebrakehoseisnottwistedor
kinkedatanypoint.Alsobesurethehoseisclear
BRAKES 5-17
ofallsteeringandsuspensioncomponents.Loosen
andrepositionthehoseifnecessary.
(6)Installwheelandtireassembly.
(7)Fillmastercylinderandbleedbasebrakesystem.
DISCBRAKESHOES
REMOVAL
(1)Raisevehicleandremovefrontwheelandtire
assemblies.
(2)Drainsmallamountoffluidfrommastercylin-
derfrontbrakereservoirwithsuctiongun.
(3)BottomcaliperpistoninborewithC-clamp.
Positionclampscrewonoutboardbrakeshoeand
clampframeonrearofcaliper.TypicalC-clamp
attachmentisshownin(Fig.24).Donotallow
clampscrewtobeardirectlyonoutboardshoe
retainerspring.Usewoodormetalspacer
betweenshoeandclampscrewifnecessary.
Fig.24BottomingCaliperPistonWithC-Clamp
(4)Removecalipermountingbolts(Fig.25).
CALIPER
Fig.25CaliperMountingBolts
CALIPER
MOUNTING
BOLT(2)
J9105-31

54. 5-18

BRAKES
REMOVAL ANDINSTALLATION (Continued)
(5)Tilttopofcaliperoutwardwithprytoolifnec-
essary(Fig.26)andremovecaliper.
Fig.26CaliperRemoval
TILT
CALIPER
OUTBOARD
TOREMOVE
J9005-30
(6)Removeoutboardshoebypressingoneendof
shoeinwardtodisengageshoelug.Thenrotateshoe
upwarduntilretainerspringclearscaliper.Press
oppositeendofshoeinwardtodisengageshoelug
androtateshoeupandoutofcaliper(Fig.27).
LOCATING
LUG
Fig.27OutboardBrakeShoeRemoval
J9005-83
(7)Removeinboardshoe.Graspendsofshoeand
tiltshoeoutwardtoreleasespringsfromcaliperpis-
ton(Fig.28).Thenremoveshoefromcaliper.
NOTE:Iforiginalbrakeshoeswillbeused,keep
theminsets(leftandright).
(8)Securecalipertonearbysuspensionpartwith
wire.Donotallowbrakehosetosupportcaliper
weight.
(9)Wipecaliperoffwithshopragsortowels.Do
notusecompressedair.
Fig.28InboardBrakeShoeRemoval
INSTALLATION
(1)Cleanbrakeshoemountingledgeslidesurfaces
ofsteeringknucklewithwirebrush.Thenapplylight
coatofhightemperaturemulti-purposegreaseto
slidesurfaces.Lubricatemountingboltsandbush-
ingssiliconegrease(Fig.29).
11
l~
CALIPER
AMOUNTING
s
.
BOLTS
Fig.29CaliperLubricationPoints
TJ
(2)Installinboardshoeincaliperandverifyshoe
retainingspringsarefullyseatedintothepiston.
(3)Installoutboardshoeincaliperbystartingone
endofshoeincaliperandrotatingshoedownward
intoplace.Verifyshoelocatinglugsandshoespring
areseated.
(4)Installcaliperbypositionnotchesatlowerend
ofbrakeshoesonbottommountingledge.Then
installcaliperoverrotorandseatupperendsof
brakeshoesontopmountingledge(Fig.30).
NOTE:

Beforesecuringthecaliper,besurethecal-
iperbrakehoseisnottwisted,kinkedortouching
anychassiscomponents.

55. TJ
REMOVAL ANDINSTALLATION (Continued)
CALIPER
BOLT
BOTTOM
LEDGE
Fig.30CaliperInstallation
(5)Installandtightencalipermountingboltsto15
N-m(11ft.lbs.).
CAUTION:Ifnewcaliperboltsarebeinginstalled,
orifreasonforrepairwasadragipullcondition,
checkcaliperboltlength.Iftheboltshaveashank
lengthgreaterthan67.6mm(2.66in.),theywillcon-
tacttheinboardbrakeshoecausingapartialapply
condition.Referto(Fig.31)for(correctcaliperbolt
length.
CORRECTSHANKLENGTH:
*---67 mm(±0.6mm)-
2.637in.(±0.0236in.)
22mm-
(0.866in.)
THREADLENGTH
LEDGE
~SEATEDIN
BRAKESHOE
NOTCH
RAKESHOE
BON
DGEOUTER
URFACE
Fig.31MountingBoltDimensions
19005-35
J9405-154
(6)Installwheelandtireassemblies.
(7)Pumpbrakepedaluntilcaliperpistonsand
brakeshoesareseated.
(8)Topoffbrakefluidlevelifnecessary.
DISCBRAKE ROTOR
REMOVAL
(1)Removewheelandtireassemble.
(2)Removecaliper.
(3)Removeretainerssecuringrotortohubstuds
(Fig.32).
(4)Removerotorfromhub.
(5)Ifrotorshieldrequiresservice,removefront
hubandbearingassembly.
DRUM BRAKE SHOES
ROTOR
Fig.32Rotor&Hub
BRAKES

5-19
RETAINER
BEARING
NUT
INSTALLATION
(1)Ifnewrotorisbeinginstalled,removeprotec-
tivecoatingfromrotorsurfaceswithcarburetor
cleaner.
(2)Installrotoronhub.
(3)Installcaliper.
(4)Installnewspringnutsonwheelstuds.
(5)Installwheelandtireassembly.
REMOVAL
(1)Raisevehicleandremoverearwheels.
(2)Removeanddiscardspringnutssecuring
drumstowheelstuds.
(3)Removebrakedrums.
NOTE:Ifdrumsaredifficulttoremove,backoff
adjusterthroughsupportplateaccessholewith
braketoolandscrewdriver.
(4)RemoveU-clipandwashersecuringadjuster
cabletoparkingbrakelever(Fig.33).
(5)Removeprimaryandsecondaryreturnsprings
fromanchorpinwithbrakespringpliers.
(6)Removehold-downsprings,retainersandpins
withstandardretainingspringtool.
(7)Installspringclampsonwheelcylindersto
holdpistonsinplace.

56. 5-20BRAKES
REMOVAL ANDINSTALLATION (Continued)
RIGHTREAR

TRAILING
BRAKEASSEMBLY

ADJUSTERSHOE
LEVER
SPRING
SHOECONTACT
SURFACES
SHOE
RETURN
SPRINGS
HOLDDOWN
SPRINGAND
RETAINERS
(8)Removeadjusterlever,adjusterscrewand
spring.
(9)Removeadjustercableandcableguide.
(10)Removebrakeshoesandparkingbrakestrut.
(11)Disconnectcablefromparkingbrakeleverand
removelever.
INSTALLATION
(1)Cleansupportplatewithbrakecleaner.
(2)Ifnewdrumsarebeinginstalled,removepro-
tectivecoatingwithcarburetorcleanerorbrake
cleaner.
(3)Applymulti-purposegreasetobrakeshoecon-
tactsurfacesofsupportplate(Fig:34).
Fig.34ShoeContactS~rfaces
(4)Lubricateadjusterscrewthreadsandpivot
withspraylube.
PARK
BRAKE
STRUT
ADJUSTER
SPRING
SCREW
ASSEMBLY
Y\7

Or..7
LEADING
HOLDDOWN
SHOE

SPRINGAND
RETAINERS
Fig.33DrumBrakeComponents-Typical
SUPPORT
PLATE
J9005-14
WHEELCYLINDER
CYLINDER-
TO-SUPPORTSEAL
J9005-13
TJ
(5)Attachparkingbrakelevertosecondarybrake
shoe.UsenewwasherandU-cliptosecurelever.
(6)Removewheelcylinderclamps.
(7)Attachparkingbrakecabletolever.
(8)Installbrakeshoesonsupportplate.Secure
shoeswithnewhold-downsprings,pinsandretain-
ers.
(9)Installparkingbrakestrutandspring.
(10)Installguideplateandadjustercableon
anchorpin.
(11)Installprimaryandsecondaryreturnsprings.
(12)Installadjustercableguideonsecondary
shoe.
(13)Lubricateandassembleadjusterscrew.
(14)Installadjusterscrew,springandleverand
connecttoadjustercable.
(15)Adjustshoestodrum.
(16)Installwheel/tireassembliesandlowervehi-
cle.
(17)Verifyfirmbrakepedalbeforemovingvehicle.
REMOVAL
(1)Removewheelandtireassembly.
(2)Removebrakedrum.
(3)Removewheelcylinderbrakeline.
(4)Removebrakeshoereturnspringsandmove
shoesoutofengagementwithcylinderpushrods.
(5)Removecylinderattachingboltsandremove
cylinderfromsupportplate.

57. TJ
REMOVALANDINSTALLA*ION (Continued)
INSTALLATION
(1)Applybeadofsiliconeseararoundcylinder
mountingsurfaceofsupportplat.
(2)Installcylindermountingboltsandtightento
10N-m(7ft.lbs.).
(3)Installbrakelinetocylinderandtightento16
N-m(12ft.lbs.)..
(4)Installbrakeshoereturnsring.
(5)Installbrakedrum.
(6)Installwheelandtireassembly.
(7)Bleedbasebrakesystem.
PARKINGBRAKEHANDLEVER
REMOVAL
(1)Releaseparkingbrakes.
(2)Raisevehicleonhoist.
(3)Removefrontcableadjustingnutanddisen-
gagecabletensionerfromequalizer.Thenremove
frontcablefromtensioner(Fig.3~).
(4)Lowervehicle.
(5)Removelevercoverorcenterconsoleif
equipped.RefertoGroup23Bodyforprocedures.
(6)Disconnectparkingbrakeswitchwiringcon-
nectors(Fig.36).
(7)Removescrewsattachingparkingbrakelever
tomount(Fig.37).
(8)Disengagefrontcablefromparkingbrakelever
andremoveleverassemblyfromvehicle.
Fig.35ParkingBrakeCableAttachment
L.R.
CABLE
R.R.
CABLE
80alc38a
INSTALLATION
(1)Installfrontcableonleverassembly.
(2)Installleverassemblyonmountingbracketand
tightenmountingboltsto12N-m(9ft.lbs.).
(3)Connectparkingbrakeswitchwire.
(4)Installparkinglevercover.
(5)Raisevehicle.
(6)Assemblefrontcable,cabletensionerandcable
bracket.
(7)Adjustparkingbrakefrontcable.
COVER
PARKBRAKE
LAMPSWITCH
LEVER
MOUNTING
BRACKET
Fig.37ParkingBrakeLever
(8)Lowervehicle.
REARPARKING BRAKECABLE
BRAKES

5-21
PARK
BRAKE
LEVER
Fig.36ParkingBrakeLampSwitch
PARKING
BRAKELEVER
80alc39c
FRONT
CABLE
80atc389
REMOVAL
(1)Raisevehicleandloosenequalizernutsuntil
rearcablesareslack.
(2)Disengagecablefromequalizerandremove
cable(Fig.35).
(3)Removecablebracketfromuppersuspension
arm(Fig.38).
(4)Removerearwheelandbrakedrum.
(5)Removesecondarybrakeshoeanddisconnect
cablefromleveronbrakeshoe.
(6)Compresscableretainerwithwormdrivehose
clamp(Fig.39)andremovecablefrombackingplate.

58. 5-22

BRAKES
REMOVALANDINSTALLATION (Continued)
PARKINGBRAKE
CABLE
BRACKET WIRING
BRACKET
Fig.38ParkingBrakeCableBracket
Fig.39CableRetainer
80alc39b
INSTALLATION
(1)Installnewcableinbackingplate.Besure
cableretainerisseated.
(2)Attachcabletoleveronbrakeshoeandinstall
brakeshoeonbackingplate.
(3)Adjustbrakeshoestodrumwithbrakegauge.
(4)Installbrakedrumandwheel.
(5)Installcable/bracketonuppersuspensionarm.
(6)Engagecableinequalizerandinstallequalizer
nuts.
(7)Adjustparkingbrakes.
DISASSEMBLY ANDASSEMBLY
MASTERCYLINDERRESERVOIR
REMOVAL
(1)Removereservoircapandemptyfluidinto
draincontainer.
(2)Removepinsthatretainreservoirtomastercylin-
der.Usehammerandpinpunchtoremovepins(Fig.40).
III1111111111
PIN
PUNCH
ROLLPINS
J9505-77
Fig.40ReservoirRetainingPins
RESERVOIR
BODY
TJ
(3)Clampcylinderbodyinvisewithbrassprotec-
tivejaws.
(4)Loosenreservoirfromgrommetswithprytool
(Fig.41).
PRY
TOOL
MASTER
CYLINDER
BODY

J9505-47
Fig.41LooseningReservoir
(5)Removereservoirbyrockingittoonesideand
pullingfreeofgrommets(Fig.42).
(6)Removeoldgrommetsfromcylinderbody(Fig.43).
INSTALLATION
CAUTION:Donotuseanytypeoftooltoinstall
thegrommets.Toolsmaycut,ortearthegrommets
creatingaleakproblemafterinstallation.Installthe
grommetsusingfingerpressureonly.

59. TJ
DISASSEMBLY ANDASSEMBLY (Continued)
557
GROMMETS') J/~'/
Fig.42ReservoirRemoval
DISCBRAKECALIPER
GROM~TS

t/
Fig.43GrommetRemoval
(1)Lubricatenewgrommetswthcleanbrakefluid
andInstallnewgrommetsincylinderbody(Fig.44).
Usefingerpressuretoinstallanseatgrommets.
Fig.44GrommetInstallation
DISASSEMBLY
(1)Removebrakeshoesfromcaliper.
(2)Drainbrakefluidoutofcaliper.
RESERVOIR
J9505-48
WORKNEWGROMMETS
INTOPLACEUSING
FINGERPRESSURE
ONLY
(2)Startreservoiringrommets.Thenrockreser-
voirbackandforthwhilepressingdownwardtoseat
itingrommets.

I
(3)Installpinsthatretainrese

oirtocylinderbody.
(4)Fillandbleedmastercylineronbenchbefore
installationinvehicle.
(3)Padinteriorofcaliperwithminimum,2.54cm(1
in.)thicknessofshoptowelsorrags(Fig.45).Towels
areneededtoprotectcaliperpistonduringremoval.
Fig.45PaddingCaliperInterior
BRAKES

5-23
(4)Removecaliperpistonwithshortburstsof
lowpressurecompressedair.Directairthroughfluid
inletportandeasepistonoutofbore(Fig.46).
CAUTION:Donotblowthepistonoutoftheborewith
sustainedairpressure.Thiscouldresultinacracked
piston.Useonlyenoughairpressuretoeasethepis-
tonout.NEVERattempttocatchthepistonasit
leavesthebore.Thiswillresultinpersonalinjury.
Fig.46CaliperPistonRemoval
(5)Removecaliperpistondustbootwithsuitable
tool(Fig.47)anddiscardboot.
(6)Removecaliperpistonsealwithwoodorplastic
tool(Fig.48)anddiscardseal.Donotusemetaltools
astheywillscratchpistonbore.

60. 5-24 BRAKES
DISASSEMBLY ANDASSEMBLY (Continued)
COLLAPSEBOOT
WITHPUNCH
ORSCREWDRIVER
Fig.47CaliperPistonDustBootRemoval
Fig.48PistonSealRemoval
(7)Removecalipermountingboltbushingsand
boots(Fig.49).
CALIPER
SLIDE
BUSHING
BOOT
J9005-73
Fig.49MountingBoltBushingAndBoot
ASSEMBLY
(1)Coatcaliperpistonbore,newpistonsealand
pistonwithcleanbrakefluid.
(2)Lubricatecaliperbushings,andinteriorof
bushingbootswithDielectricsiliconegrease.
I
TJ
(3)Installbushingbootsincaliper,theninsert
bushingintobootandpushbushingintoplace(Fig.
50).
BOOT
Fig.50BushingsAndBootsInstallation
(4)Installnewpistonsealintosealgroovewith
finger(Fig.51).
Fig.51PistonSealInstallation
(5)Installdustbootoncaliperpistonandseatboot
inpistongroove(Fig.52).
PISTON
Fig.52DustBootOnPiston
DUST
BOOT
J9005-75

61. TJ
DISASSEMBLY ANDASSEMBLY (Continued)
(6)Presspistonintocaliperborebyhand,usea
turnandpushmotiontoworkpistonintoseal(Fig.
53).
PISTON
BOOT
WHEELCYLINDER
Fig.53CaliperPistonIn''stallation
Fig.54PistonDustBootInstallation
(9)Replacecaliperbleedscrewifremoved.
J9105-32
(7)Presscaliperpistontobottomofbore.
(8)SeatdustbootincaliperwithInstallerTool
C-4842andToolHandleC-4171(Fig.54).
DISASSEMBLY
(1)Removepushrodsandboots(Fig.55).
(2)Presspistons,cupsandspringandexpander
outofcylinderbore.
(3)Removebleedscrew.
SPRING

PISTON
CYLINDER
CLEANING ANDINSPECTION
CALIPER
BRAKES

5-25
CUP
Fig.55WheelCylinderComponents
BOOT
PISTON
BLEEDSCREW

PUSHROD

J9005-66
ASSEMBLY
(1)Lubricatewheelcylinderbore,pistons,piston
cupsandspringandexpanderwithcleanbrakefluid.
(2)Installfirstpistonincylinderbore.Then
installfirstcupinboreandagainstpiston.Besure
lipofpistoncupisfacinginward(toward
springandexpander)andflatsideisagainst
piston.
(3)Installspringandexpanderfollowedby
remainingpistoncupandpiston.
(4)Installbootsoneachendofcylinderandinsert
pushrodsinboots.
(5)Installcylinderbleedscrew.
CLEANING
Cleanthecalipercomponentswithcleanbrake
fluidorbrakecleanonly.Donotusegasoline,kero-
sene,thinner,orsimilarsolvents.Theseproducts
mayleavearesiduethatcoulddamagethepiston
andseal.
Wipethecaliperandpistondrywithlintfreetow-
elsoruselowpressurecompressedair.
INSPECTION
Thepistonismadefromaphenolicresin(plastic
material)andshouldbesmoothandclean.
Replacethepistonifcrackedorscored.Donot
attempttorestoreascoredpistonsurfacebysanding
orpolishing.Thepistonmustbereplacedifdamaged.
NOTE:Ifthecaliperpistonmustbereplaced,
installthesametypeofpistoninthecaliper.Never
interchangephenolicresinandsteelcaliperpis-
tons.Thepistons,seals,sealgrooves,caliperbore
andpistontolerancesaredifferentforresinand
steelpistons.Donotintermixthesecomponentsat
anytime.

62. 5-26 BRAKES
CLEANING ANDINSPECTION (Continued)
Theborecanbelightlypolishedwithabrakehone
toremoveveryminorsurfaceimperfections(Fig.56).
Thecalipershouldbereplacediftheboreisseverely
corroded,rusted,scored,orifpolishingwould
increaseborediametermorethan0.025mm(0.001
inch).
REARDRUMBRAKE
Fig.56LightlyPolishingPistonBoreWithTool
CLEANING
Cleantheindividualbrakecomponents,including
thesupportplateandwheelcylinderexterior,witha
waterdampenedclothorwithbrakecleaner.Donot
useanyothercleaningagents.Removelightrustand
scalefromthebrakeshoecontactpadsonthesup-
portplatewithfinesandpaper.
INSPECTION
Asageneralrule,rivetedbrakeshoesshouldbe
replacedwhenworntowithin0.78mm(1/32in.)of
therivetheads.Bonded'liningshouldbereplaced
whenworntoathicknessof1.6mm(1/16in.).
Examinetheliningcontactpatterntodetermineif
theshoesarebentorthedrumistapered.Thelining
shouldexhibitcontactacrossitsentirewidth.Shoes
exhibitingcontactonlyononesideshouldbe
replacedandthedrumcheckedforrunoutortaper.
Inspecttheadjusterscrewassembly.Replacethe
assemblyifthestarwheelthreadsaredamaged,or
thecomponentsareseverelyrustedorcorroded.
Discardthebrakespringsandretainercomponents
ifworndistorted,orcollapsed:Alsoreplacethe
springsifabrakedragconditionhadoccurred.Over-
heatingwilldistortandweakenthesprings.
Inspectthebrakeshoecontactpadsonthesupport
plate,replacethesupportplateif'anyofthepadsare
wornorrustedthrough.Alsoreplacetheplateifitis
bentordistorted(Fig.57).
WHEELCYLINDER
ADJUSTMENTS
Fig.57ShoeContactSurfaces
TJ
SUPPORT
PLATE
SHOECONTACT
SURFACES

J9005-14
CLEANING
Cleanthecylinderandpistonswithcleanbrake
fluidorbrakecleaneronly.Donotuseanyother
cleaningagents.
Drythecylinderandpistonswithcompressedair.
Donotuseragsorshoptowelstodrythecylinder
components.Lintfromclothmaterialwilladhereto
thecylinderboresandpistons.
INSPECTION
Inspectthecylinderbore.Lightdiscolorationand
darkstainsintheborearenormalandwillnot
impaircylinderoperation.
Thecylinderborecanbelightlypolishedbutonly
withcrocuscloth.Replacethecylinderiftheboreis
scored,pittedorheavilycorroded.Honingtheboreto
restorethesurfaceisnotrecommended.
Inspectthecylinderpistons.Thepistonsurfaces
shouldbesmoothandfreeofscratches,scoringand
corrosion.Replacethepistonsifworn,scored,orcor-
roded.Doattempttorestorethesurfacebysanding
orpolishing.
Discardtheoldpistoncupsandthespringand
expander.Thesepartsarenotreusable.Theoriginal
dustbootsmaybereusedbutonlyiftheyareingood
condition.
STOPLAMPSWITCH
(1)Pressandholdbrakepedalinappliedposition.
(2)Pullswitchplungerallthewayouttofully
extendedposition.
(3)Releasebrakepedal.Thenpullpedalfullyrear-
ward.Pedalwillsetplungertocorrectpositionas
pedalpushesplungerintoswitchbody.Switchwill
makerachetingsoundasitselfadjusts.

63. TJ
ADJUSTMENTS (Continued)
PARKINGBRAKECABLETENSIOINER
NOTE:Parkingbrakeadjustment)isonlynecessary
whenthetensioner,oracablehaysbeenreplacedor
disconnectedforservice.Whenadjustmentisnec-
essary,performthefollowingprocedureforproper
parkingbrakeoperation.
ADJUSTMENT
(1)Raisevehicle.
(2)Backofftensioneradjustingi!inuttocreateslack
incables.
(3)Removerearwheel/tireassembliesandremove
brakedrums.
(4)Checkrearbrakeshoeadjustmentwithstan-
dardbrakegauge.Excessiveshoe-to-drumclear-
ance,orwornbrakecomponentswillresultin
faultyparkingbrakeadjustmentandoperation.
(5)Verifythatparkingbrakecablesoperatefreely
andarenotbinding,orseized.Replacefaultycables,
beforeproceeding.
(6)Reinstallbrakedrumsandwheel/tireassem-
bliesafterbrakeshoeadjustmentiscomplete.
(7)Lowervehicleenoughforaccesstoparking
brakelever.Thenfullyapplyparkingbrakes.Leave
brakesapplieduntiladjustmentiscomplete.
(8)Raisevehicleandmarktensionerrod6.5mm
(1/4in.)fromtensionerbracket(Fig.58).
(9)Tightenadjustingnutatequalizeruntilmark
ontensionerrodmovesintoalignmentwithtensioner
bracket.
(10)Lowervehicleuntilrearwheelsare15-20cm
(6-8in.)offshopfloor.
(11)Releaseparkingbrakeleverandverifythat
rearwheelsrotatefreelywithoutdrag.
(12)Lowervehicle.
NOTE:Donotloosen/tightenequalizeradjusting
nutforanyreasonaftercompletingadjustment.
Fig.58TensionerRodMeasurement
J9405-158
REARDRUMBRAKE
Thereardrumbrakesareequippedwithaself-ad-
justingmechanism.Undernormalcircumstances,the
onlytimeadjustmentisrequirediswhentheshoes
arereplaced,removedforaccesstootherparts,or
whenoneorbothdrumsarereplaced.
Adjustmentcanbemadewithastandardbrake
gaugeorwithadjustingtool.Adjustmentisper-
formedwiththecompletebrakeassemblyinstalled
onthebackingplate.
ADJUSTMENT WITHBRAKEGAUGE
(1)Besureparkingbrakesarefullyreleased.
(2)Raiserearofvehicleandremovewheelsand
brakedrums.
(3)Verifythatleftandrightautomaticadjuster
leversandcablesareproperlyconnected.
(4)Insertbrakegaugeindrum.Expandgauge
untilgaugeinnerlegscontactdrumbrakingsurface.
Thenlockgaugeinposition(Fig.59).
BRAKES

5-27
Fig.59AdjustingGaugeOnDrum
(5)Reversegaugeandinstallitonbrakeshoes.
Positiongaugelegsatshoecentersasshown(Fig.
60).Ifgaugedoesnotfit(tooloose/tootight),adjust
shoes.
(6)Pullshoeadjusterscrewstarwheelawayfrom
adjusterlever.
(7)Turnadjusterscrewstarwheel(byhand)to
expandorretractbrakeshoes.Continueadjustment
untilgaugeoutsidelegsarelightdrag-fitonshoes.
(8)Installbrakedrumsandwheelsandlower
vehicle.
(9)Drivevehicleandmakeoneforwardstopfol-
lowedbyonereversestop.Repeatprocedure8-10
timestooperateautomaticadjustersandequalize
adjustment.

64. 5-28

BRAKES
ADJUSTMENTS (Continued)
BRAKESHOES
Fig.60AdjustingGaugeOnBrakeShoes
NOTE:Bringvehicletocompletestandstillateach
stop.Incomplete,rollingstopswillnotactivate
automaticadjusters.
ADJUSTMENT WITHADJUSTINGTOOL
(1)Besureparkingbrakeleverisfullyreleased.
(2)Raisevehiclesorearwheelscanberotated
freely.
(3)Removeplugfromeachaccessholeinbrake
supportplates.
(4)Loosenparkingbrakecableadjustmentnut
untilthereisslackinfrontcable.
(5)Insertadjustingtoolthroughsupportplate
accessholeandengagetoolinteethofadjusting
screwstarwheel(Fig.61).
Fig.61BrakeAdjustment
(6)Rotateadjusterscrewstarwheel(movetool
handleupward)untilslightdragcanbefeltwhen
wheelisrotated.
SPECIFICATIONS
BRAKEFLUID
BRAKECOMPONENTS
TJ
(7)Pushandholdadjusterleverawayfromstar
wheelwiththinscrewdriver.
(8)Backoffadjusterscrewstarwheeluntilbrake
dragiseliminated.
(9)Repeatadjustmentatoppositewheel.Besure
adjustmentisequalatbothwheels.
(10)Installsupportplateaccessholeplugs.
(11)Adjustparkingbrakecableandlowervehicle.
(12)Installbrakedrumsandwheelsandlower
vehicle.
(13)Drivevehicleandmakeoneforwardstopfol-
lowedbyonereversestop.Repeatprocedure8-10
timestooperateautomaticadjustersandequalize
adjustment.
NOTE:Bringvehicletocompletestandstillateach
stop.Incomplete,rollingstopswillnotactivate
automaticadjusters.
Thebrakefluidusedinthisvehiclemustconform
toDOT3specificationsandSAEJ1703standards.
Noothertypeofbrakefluidisrecommendedor
approvedforusageinthevehiclebrakesystem.Use
onlyMoparbrakefluidoranequivalentfroma
tightlysealedcontainer.
CAUTION:Neverusereclaimedbrakefluidorfluid
fromancontainerwhichhasbeenleftopen.An
opencontainerwillabsorbmoisturefromtheair
andcontaminatethefluid.
CAUTION:Neveruseanytypeofapetroleum-
basedfluidinthebrakehydraulicsystem.Useof
suchtypefluidswillresultinsealdamageofthe
vehiclebrakehydraulicsystemcausingafailureof
thevehiclebrakesystem.
DiscBrakeCaliper
Type...............................Sliding
DiscBrakeRotor
Type

............................Ventilated
Max.Runout...............0.12mm(0.005in.)
Max.ThicknessVariation...0.013mm(0.0005in.)
BrakeDrum
Size.............................9x2.5in.
BrakeBooster
Type.....................TandemDiaphragm

65. TJ

BRAKES 5-29
SPECIFICATIONS (Continujed)
TORQUECHART

SPECIAL TOOLS
DESCRIPTION

TORQUE

BASEBRAKES
BrakePedal
SupportBolt..............',.28N-m(21ft.lbs.)
BrakeBooster
MountingNuts.............'37N-m(27ft.lbs.)
MasterCylinder
MountingNuts............11.24N-m(18ft.lbs.)
BrakeLines...............1.15N-m(11ft.lbs.)
CombinationValve
MountingNuts..
.
.........II,.24N-m(18ft.lbs.)
BrakeLines...............1.21N-m(15ft.lbs.)
Caliper

InstallerCaliperDustBootC-4842
MountingBolts............',,.15N-m(11ft.lbs.)
BrakeHoseBolt...........1.31N-m(23ft.lbs.)
WheelCylinder
MountingBolts..............10N-m(7ft.lbs.)
BrakeLine................'16N-m(12ft.lbs.)
ParkingBrake
LeverBolts.................12N-m(9ft.lbs.)
LeverBracketBolts...........'12N-m(9ft.lbs.)
CableRetainerNut.........1.5N-m(14in.lbs.)
HandleC-4171

66. 5-30 BRAKES
page
GENERALINFORMATION
ANTILOCKBRAKESYSTEM...............30
DESCRIPTIONANDOPERATION
ABSSYSTEMRELAYS....................33
ABSWARNINGLAMP....................33
ACCELERATION SWITCH.................33
ANTILOCKBRAKESYSTEM...............30
COMBINATIONVALVE....................33
CONTROLLER ANTILOCKBRAKES..........31
HYDRAULICCONTROLUNIT...............31
WHEELSPEEDSENSORSANDTONEWHEEL.32
DIAGNOSISANDTESTING
ANTILOCKBRAKES......................33
GENERAL INFORMATION
ANTILOCKBRAKESYSTEM
Theantilockbrakesystem(ABS)isanelectroni-
callyoperated,allwheelbrakecontrolsystem.
Thesystemisdesignedtopreventwheellockup
andmaintainsteeringcontrolduringperiodsofhigh
wheelslipwhenbraking.Preventinglockupisaccom-
plishedbymodulatingfluidpressuretothewheel
brakeunits.
Thehydraulicsystemisathreechanneldesign.
Thefrontwheelbrakesarecontrolledindividually
andtherearwheelbrakesintandem(Fig.1).The
ABSelectricalsystemisseparatefromotherelectri-
calcircuitsinthevehicle.Aspeciallyprogrammed
controllerantilockbrakeunitoperatesthesystem
components.
,ABSsystemmajorcomponentsinclude:
ControllerAntilockBrakes(CAB)
"HydraulicControlUnit(HCU)
"WheelSpeedSensors(WSS)
AccelerationSwitch
"MainRelayAndPumpMotorRelay
"ABSWarningLight
"PumpMotorSensor
DIESCRIPTION ANDOPERATION
ANTILOCKBRAKESYSTEM
BatteryvoltageissuppliedtotheCABignitionter-
minalwhentheignitionswitchisturnedtoRunposi-
tion.TheCABperformsasysteminitialization
procedureatthispoint.Initializationconsistsofa
ANTILOCK BRAKES
INDEX
TJ
page
SERVICEPROCEDURES
BLEEDINGABSBRAKESYSTEM

...........33
REMOVALANDINSTALLATION
ACCELERATION SWITCH.................36
COMBINATIONVALVE............
.....
...36
CONTROLLER ANTILOCKBRAKES..........34
FRONTWHEELSENSOR.....
...
.....
.....
34
HYDRAULICCONTROLLER UNIT...........34
REARWHEELSPEEDSENSOR

............35
SPECIFICATIONS
TORQUECHART........................37
POWERBRAKE

ACCELERATION
MASTER BOOSTER SWITCH
CYLINDER NI,

1 .CAB
AND
RESERVOIR
COMBINATION
VALVE
WIRESTO
`JrFWHEEL
HCU %;; SPEED
HARNESS SENSORS
HYDRAULIC~`-..._
BRAKELINES

'
TOWHEELS
Fig.1AntilockBrakeSystem
staticanddynamicselfcheckofsystemelectrical
components.
Thestaticcheckoccursaftertheignitionswitchis
turnedtoRunposition.Thedynamiccheckoccurs
whenvehicleroadspeedreachesapproximately10
kph(6mph).Duringthedynamiccheck,theCAB
brieflycyclesthepumpandsolenoidstoverifyoper-
ation.
IfanABScomponentexhibitsafaultduringini-
tialization,theCABilluminatestheamberwarning
lightandregistersafaultcodeinthemicroprocessor
memory.

67. TJ
DESCRIPTION ANDOPERATION (Continued)
NORMAL BRAKING

i
TheCABmonitorswheelspeedsensorinputscon-
tinuouslywhilethevehicleisinmotion.However,
theCABwillnotactivateanyALBScomponentsas
longassensorinputsandtheaccelerationswitch
indicatenormalbraking.
Duringnormalbraking,themastercylinder,power
boosterandwheelbrakeunitsallfunctionasthey
wouldinavehiclewithoutABS.'TheHCUcompo-
nentsarenotactivated.
ANTILOCK BRAKING
Thepurposeoftheantilocksystemistoprevent
wheellockupduringperiodsofhighwheelslip.Pre-
ventinglockuphelpsmaintainvehiclebrakingaction
andsteeringcontrol.
TheantilockCABactivatesthesystemwhenever
sensorsignalsindicateperiodso,'fhighwheelslip.
Highwheelslipcanbedescribedasthepointwhere
wheelrotationbeginsapproachingzero(orlockup)
duringbraking.Periodsofhighwheelslipoccur
whenbrakestopsinvolvehighpedalpressureand
rateofvehicledeceleration.
Theantilocksystempreventslockupduringhigh
slipconditionsbymodulatingfluidapplypressureto
thewheelbrakeunits.
Brakefluidapplypressureismodulatedaccording
towheelspeed,degreeofslipandrateofdecelera-
tion.Asensorateachwheelconvertswheelspeed
intoelectricalsignals.Thesesignalsaretransmitted
totheCABforprocessinganddeterminationof
wheelslipanddecelerationrate.
TheABSsystemhasthreefluidpressurecontrol
channels.Thefrontbrakesarecontrolledseparately
andtherearbrakesintandem.Aspeedsensorinput
signalindicatingahighslipconditionactivatesthe
CABantilockprogram.
Twosolenoidvalvesareusedin'eachantilockcon-
trolchannel.Thevalvesarealllocatedwithinthe
HCUvalvebodyandworkinpairstoeitherincrease,
hold,ordecreaseapplypressure'asneededinthe
individualcontrolchannels.
Thesolenoidvalvesarenotstaticduringantilock
braking.Theyarecycledcontinuouslytomodulate
pressure.Solenoidcycletimeinantilockmodecanbe
measuredinmilliseconds.
CONTROLLERANTILOCKBRAKES
TheCABislocatedundertheinstrumentpanelto
therightsideofthesteeringcolumn.Itismounted
tobracketwithonebolt.Thebracketismountedto
thefrontuppercowlpanel.
TheCABoperatestheABSsystem(Fig.2)andis
separatefromothervehicleelectricalcircuits.CAB
voltagesourceisthroughtheignitionswitchinthe
RUNposition.
BRAKES

5-31
TheCABcontainsdualmicroprocessors.Alogic
blockineachmicroprocessorreceivesidenticalsensor
signals.Thesesignalsareprocessedandcompared
simultaneously.
TheCABcontainsaselfcheckprogramthatillu-
minatestheABSwarninglightwhenasystemfault
isdetected.Faultsarestoredinadiagnosticprogram
memoryandareaccessiblewiththeDRBscantool.
ABSfaultsremaininmemoryuntilcleared,or
untilafterthevehicleisstartedapproximately50
times.Storedfaultsarenoterasedifthebatteryis
disconnected.
Fig.2Controller Antilock Brakes
III

III
I

IllI'1ilir,I111IVIIlall
11yyizlil`n,i'il~nsliinZ
HYDRAULICCONTROLUNIT
Thehydrauliccontrolunit(HCU)consistsofa
valvebody,pumpbody,accumulators,pumpmotor,
andwireharnesses(Fig.3).
Thepump,motor,andaccumulatorsarecombined
intoanassemblyattachedtothevalvebody.The
accumulatorsstoretheextrafluidreleasedtothe
systemforABSmodeoperation.Thepumpprovides
thefluidvolumeneededandisoperatedbyaDC
typemotor.ThemotoriscontrolledbytheCAB.
Thevalvebodycontainsthesolenoidvalves.The
valvesmodulatebrakepressureduringantilockbrak-
ingandarecontrolledbytheCAB.
TheHCUprovidesthreechannelpressurecontrol
tothefrontandrearbrakes.Onechannelcontrols
therearwheelbrakesintandem.Thetworemaining
channelscontrolthefrontwheelbrakesindividually.
Duringantilockbraking,thesolenoidvalvesare
openedandclosedasneeded.Thevalvesarenot
static.Theyarecycledrapidlyandcontinuouslyto
modulatepressureandcontrolwheelslipanddecel-
eration.
Duringnormalbraking,theHCUsolenoidvalves
andpumparenotactivated.Themastercylinderand
powerboosteroperatethesameasavehiclewithout
anABSbrakesystem.

68. 5-32BRAKES
DESCRIPTIONANDOPERATION(Continued)
PUMP
MOTOR
Fig.3HydraulicControllerUnit
Duringantilockbraking,solenoidvalvepressure
modulationoccursinthreestages,pressureincrease,
pressurehold,andpressuredecrease.Thevalvesare
allcontainedinthevalvebodyportionoftheHCU.
PressureDecrease
Theoutletvalveisopenedandtheinletvalveis
closedduringthepressuredecreasecycle.
Apressuredecreasecycleisinitiatedwhenspeed
sensorsignalsindicatehighwheelslipatoneor
morewheels.Atthispoint,theCABopenstheoutlet
valve,whichalsoopensthereturncircuittotheaccu-
mulators.Fluidpressureisallowedtobleedoff
(decrease)asneededtopreventwheellock.
Oncetheperiodofhighwheelsliphasended,the
CABclosestheoutletvalveandbeginsapressure
increaseorholdcycleasneeded.
PressureHold
Bothsolenoidvalvesareclosedinthepressure
holdcycle.Fluidapplypressureinthecontrolchan-
nelismaintainedataconstantrate.TheCABmain-
tainstheholdcycleuntilsensorinputsindicatea
pressurechangeisnecessary.
PressureIncrease
Theinletvalveisopenandtheoutletvalveis
closedduringthepressureincreasecycle.Thepres-
sureincreasecycleisusedtocounteractunequal
wheelspeeds.Thiscyclecontrolsre-applicationof
fluidapplypressureduetochangingroadsurfacesor
wheelspeed.
WHEELSPEEDSENSORSANDTONEWHEEL
80al8d54
Aspeedsensorisusedateachwheel.Thefront
sensorsaremountedtothesteeringknuckles.The
rearsensorsaremountedtothe,rearbrakebacking
plate.

j
ThesensorsconvertwheelspeedintoasmallAC
electricalsignal.Thissignalistransmittedtothe
CAB.TheCABconverttheACsignalintoadigital
signalforeachwheel.Thisvoltageisgeneratedby
magneticinductionwhenatonewheelpassesbythe
stationarymagneticofthewheelspeedsensor.
Ageartypetoneringservesasthetriggermecha-
nismforeachsensor.Thetoneringsaremountedat
theoutboardendsofthefrontandrearaxleshafts.
Differentsensorsareusedatthefrontandrear
wheels(Fig.4).Thefront/rearsensorshavethesame
electricalvaluesbutarenotinterchangeable.The
sensorshavearesistancebetween900and1300
ohms.
SPEEDSENSORAIRGAP
PICKUP
FACE J9205-6
Fig.4TypicalWheelSpeedSensors
TJ
FrontSensor
Frontsensorairgapisfixedandnotadjustable.
Onlyrearsensorairgapisadjustable.
Althoughfrontairgap,isnotadjustable,itcanbe
checkedifdiagnosisindicatesthisisnecessary.Front
airgapshouldbe0.40to1.3mm(0.0157to0.051
in.).Ifgapisincorrect,thesensoriseitherloose,or
damaged.
RearSensor
Arearsensorairgapadjustmentisonlyneeded
whenreinstallinganoriginalsensor.Replacement
sensorshaveanairgapspacerattachedtothesensor
pickupface.Thespacerestablishescorrectairgap
whenpressedagainstthetoneringduringinstalla-
tion.Asthetoneringrotates,itpeelsthespaceroff
thesensortocreatetherequiredairgap.Rearsensor
airgapis0.28-1.5mm(0.011-0.059in.).
Sensorairgapmeasurement,oradjustmentproce-
duresareprovidedinthissection.Refertothefront,
orrearsensorremovalandinstallationproceduresas
required.

69. TJ
DESCRIPTION ANDOPERATION (Continued)
COMBINATIONVALVE
Thecombinationvalvecontainsapressurediffer-
entialvalveandswitchandarearbrakeproportion-
ingvalve.Thevalveisnotrepairable.Itmustbe
replacedifdiagnosisindicatesthusisnecessary.
Thepressuredifferentialswitchisconnectedtothe
brakewarninglight.Theswitchisactuatedbymove-
mentoftheswitchvalve.Theswitchmonitorsfluid
pressureintheseparatefront/rearbrakehydraulic
circuits.
Adecreaseorlossoffluidpressureineither
hydrauliccircuitwillcausetheswitchvalvetoshut-
tletothelowpressureside.Movementofthevalve
pushestheswitchplungerupward.Thisactioncloses
theswitchinternalcontactscompletingtheelectrical
circuittotheredwarninglight.Theswitchvalvewill
remaininanactuatedpositionuntilrepairsare
made.
Therearproportioningvalveisusedtobalance
front-rearbrakeaction.Thevalveallowsnormal
fluidflowduringmoderateeffortbrakestops.The
valveonlycontrols(meters)fluidflowduringhigh
effortbrakestops.
ACCELERATIONSWITCH
Theaccelerationswitchislocatedinfrontofthe
console/shiftermountedtoabracketonthefloorpan.
Theswitch(Fig.5),providesanadditionalvehicle
decelerationreferenceduring4-wheeldriveopera-
tion.TheswitchismonitoredbytheCABatall
times.Theswitchreferencesignalisutilizedbythe
CABwhenallwheelsaredeceleratingatthesame
speed.
Fig.5AccelerationSwitch
ARROWINDICATES
FRONTOFSWITCH
FORPROPERMOUNTING
ABSSYSTEMRELAYS
TheABSbrakeshastworelays,whicharethesys-
temandpumpmotorrelays.TheABSsystemrelayis
usedforthesolenoidvalvesandCAB.Thesystem
relayisconnectedtotheCABatthepowercontrol
relayterminal.Thepumpmotorrelayisusedforthe
pumpmotoronly.Thepumpmotorrelaystarts/stops
thepumpmotorwhensignaledbytheCAB.
Therelaysarelocatedinthepowerdistribution
boxintheenginecompartment.
ABSWARNINGLAMP
TheamberABSwarninglampislocatedinthe
instrumentcluster.Thelampilluminatesatstart-up
toperformaselfcheck.Thelampgoesoutwhenthe
selfcheckprogramdeterminesthesystemisoperat-
ingnormal.IfanABScomponentexhibitsafaultthe
CABwillilluminatethelampandregisteratrouble
codeinthemicroprocessor.Thelampiscontrolledby
theCABandorthemainrelaythroughanin-har-
nessdiode.TheCABcontrolsthelampbydirectly
groundingthecircuit.Themainrelaygroundsthe
lampcircuitwhenitisde-energized.
DIAGNOSISANDTESTING
ANTILOCKBRAKES
BRAKES5-33
TheABSbrakesystemperformsseveralself-tests
everytimetheignitionswitchisturnedonandthe
vehicleisdriven.TheCABmonitorsthesystems
inputandoutputcircuitstoverifythesystemisoper-
atingcorrectly.Iftheonboarddiagnosticsystem
sensesthatacircuitismalfunctioningthesystem
willsetatroublecodeinitsmemory.
NOTE:TheMDSorDRBIIIscantoolisusedto
diagnosetheABSsystem.Foradditionalinforma-
tionrefertotheAntilockBrakesectioninGroup
SW.FortestproceduresrefertotheChassisDiag-
nosticManual.
SERVICEPROCEDURES
BLEEDINGABSBRAKESYSTEM
ABSsystembleedingrequiresconventionalbleed-
ingmethodsplususeoftheDRBscantool.Thepro-
cedureinvolvesperformingabasebrakebleeding,
followedbyuseofthescantooltocycleandbleedthe
HCUpumpandsolenoids.Asecondbasebrakebleed-
ingprocedureisthenrequiredtoremoveanyair
remaininginthesystem.
(1)Performbasebrakebleeding.Refertobase
brakesectionforprocedure.
(2)ConnectscantooltoABSdiagnosticconnector
undercarpetatfrontofconsole,justunderinstru-
mentpanelcenterbezel.
(3)SelectCHASSISSYSTEM,followedbyTEVES
ABSBRAKES,thenBLEEDBRAKES.Whenscan

70. 5-34BRAKES
SERVICEPROCEDURES (Continued)
tooldisplaysTESTCOMPLETE, disconnectscantool
andproceed.
(4)Performbasebrakebleedingasecondtime.
Refertobasebrakesectionforprocedure.
(5)Topoffmastercylinderfluidlevelandverify
properbrakeoperationbeforemovingvehicle.
REMOVALANDINSTALLATION
CONTROLLERANTILOCKBRAKES
REMOVAL
(1)Removenegativebatteryterminal.
(2)RemovetheharnessconnectorfromtheCAB
locatedunderneaththeinstrumentpanel(Fig.6).
(3)RemovemountingboltandremovetheCAB.
Fig.6ControllerAntilockBrakes
INSTALLATION
(1)Installthecontroller
bolt.
(2)Tightenthemountingboltto8N-m(70in.
lbs.).
(3)Plugintheharnessconnectorintothecontrol-
ler.
(4)Installnegativebatterycable.
HYDRAULICCONTROLLERUNIT
andinstallthemounting
REMOVAL
(1)Disconnectandisolatethenegativebatteryter-
minal.
(2)DisconnecttheHCUharnessconnectors.
(3)RemoveallthebrakelinesfromtheHCU(Fig.
7).
(4)RemoveHCUmountingboltsandremoveHCU
(Fig.8).
(5)Removeboltsfrommountandremovemount
fromHCU.
COMBINATION
VALVE
FRONTWHEELSENSOR
Fig.7HCUBrakeLines
Fig.8HCUMount
MASTER
CYLINDER
HCU
TJ
80al8d4c
INSTALLATION
(1)InstallmountonHCUandtightento6.5N-m
(57in.lbs.).
(2)InstallHCUandtightenmountingboltsto20
N-m(177in.lbs.).
(3)Alignandstartbrakelinefittingsbyhandto
avoidcrossthreading.
(4)Tightenbrakelinesto16N-m(144in.lbs.).
(5)ConnectHCUharness.
(6)Connectnegativebatteryterminal.
(7)Bleedcompletebrakesystem.
REMOVAL
(1)Raisevehicleandturnwheeloutwardtoaccess
thesensor.
(2)Disconnectsensorwireconnectoratharness
plug..
(3)Removesensorwirefrommountingretainers.
(4)Cleansensorandsurroundingareawithshop
towelbeforeremoval.

71. TJ
REMOVAL AND INSTALLATION (Continued)
(5)Removeboltattachingsensortosteering
knuckleandremovesensor(Fig.9).
WHEELSPEED

STEERING
SENSORPIGTAIL

KNUCKLE
FRONTWHEEL
SPEEDSENSOR
REARWHEELSPEEDSENSOR
Fig.9FrontWheelSpeedSensor
8031e865
INSTALLATION
(1)Iforiginalsensorwillbeinstalled,wipeall
tracesofoldspacermaterialoffsensorpickupface.
Useadryshoptowelforthispurpose.
(2)ApplyMoparLockN'SealorLoctite242tobolt
thatsecuressensorinsteeringknuckle.Usenew
sensorboltiforiginalboltiswornordamaged.
(3)Positionsensoronsteeringknuckle.Seatsen-
sorlocatingtabinholeinknuckleandinstallsensor
attachingboltfingertight.
(4)Tightensensorattachingboltto14N-m(11ft.
lbs.).
(5)Iforiginalsensorhasbeeninstalled,checksen-
sorairgap.Airgapshouldbe0.40to1.3mm(0.0157
to0.051in.).Ifgapisincorrect,sensoriseitherloose,
ordamaged.
(6)Routesensorwireandinstallintomounting
retainers.
(7)Connectsensorwiretoharness.
REMOVAL
(1)Disconnectsensorsatrearharnessconnectors.
(2)Removewheelandtireassembly.
(3)Removebrakedrum.
(4)Removeclipssecuringsensorwirestobrake
lines,rearaxleand,brakehose.
(5)Unseatsensorwiresupportplategrommet.
(6)Removeboltattachingsensortobracketand
removesensor.
BRAKES 5-35
INSTALLATION
(1)Iforiginalsensorisbeinginstalled,remove
anyremainingpiecesofcardboardspacerfromsen-
sorpickupface.Usedryshoptowelonlytoremove
oldspacermaterial.
(2)Insertsensorwirethroughsupportplatehole.
Thenseatsensorgrommetinsupportplate.
(3)ApplyMoparLockN'SealorLoctite242to
originalsensorbolt.Usenewboltiforiginalisworn
ordamaged.
(4)Installsensorboltfingertightonlyatthis
time.
(5)Iforiginalrearsensorwasinstalled,adjust
sensorairgapto0.28-1.5mm(0.011-0.059in.).Use
feelergaugetomeasureairgap(Fig.10).Tighten
sensorboltto11N-m(11ft.lbs.).
REAR
SENSOR
Fig.11NewRearSensor
Fig.10SettingAirGapOnOriginalRearSensor
(6)

Ifnewsensorwasinstalled,pushcardboard
spaceronsensorfaceagainsttonering(Fig.11).
Thentightensensorboltto8N-m(6ft.lbs.).Correct
airgapwillbeestablishedastoneringrotatesand
peelsspaceroffsensorface.
AIRGAP
SPACER
ATTACHEDTO
SENSORFACE
J9205-35
(7)Securetherearsensorwirestotheretainer
clips.Verifythatwireisclearofrotatingcomponents.
(8)Connectsensorwiretoharnessconnector.

72. 5-36

BRAKES
REMOVAL ANDINSTALLATION (Continued)
(9)Installbrakedrumandwheelandtireassem-
bly.
(10)Lowervehicle.
(11)Connectsensorwiretoharnessconnector.
COMBINATIONVALVE
REMOVAL
(1)Removebrakelinesthatconnectmastercylin-
dertocombinationvalve(Fig.12).
(2)Disconnectbrakelinesthatconnectcombina-
tionvalvetoHCU.
(3)Disconnectwirefromcombinationvalveswitch
terminal.Becarefulwhenseparatingwireconnector
aslocktabsareeasilydamagedifnotfullydisen-
gaged.
(4)Removenutsattachingcombinationvalve
brackettoboosterstudsandvalvebracketoffbooster
studs(Fig.13).
COMBINATION
VALVE
Fig.12CombinationValveBrakeLines
MASTERCYLINDER
MASTER
CYLINDER
HCU
80al8d4c
COMBINATION
VALVEBRACKET
Fig.13CombinationValveBracket
80al8d4f
INSTALLATION
(1)Positionvalvebracketonboosterstudsand
tightenbracketattachingnutsto17N-m(13ft.lbs.).
(2)Alignandstartbrakelinefittingsincombina-
tionvalve,mastercylinderandHCUbyhandto
avoidcrossthreading.
(3)Tightenbrakelinefittingsatcombinationvalve
to21N-m(15ft.lbs.).
(4)Tightenbrakelinefittingsatmastercylinder
to15N-m(11ft.lbs.).
(5)TightenbrakelinefittingsatHCUto16N-m
(12ft.lbs.).
(6)Connectwiretodifferentialpressureswitchin
combinationvalve.
(7)Bleedbasebrakesystem.
ACCELERATIONSWITCH
REMOVAL
(1)Fromthedriverssideliftcarpetbackinfront
oftheconsole/shifter.
(2)Disconnectharnessforswitch.
(3)Removemountingboltsandremoveswitch
(Fig.14).
V
ACCELERATION
SWITCH
Fig.14AccelerationSwitch
TJ
80alc38c

73. TJ
REMOVAL ANDINSTALLATION (Continued)
INSTALLATION
CAUTION:Theaccelerationswitchmustbe
installedwiththearrowpointingtowardthefrontof
thevehicle(Fig.15).Theswitchwillnotoperate
properlyinanyotherposition.
(1)Positionswitchonmountingbracket.
(2)Installmountingboltsandtightento4.5N-m
(40in.lbs.)
(3)Connectharnesstoswitch.
(4)Placecarpetbackintoposition.
ARROWINDICATES
FRONTOFSWITCH
FORPROPERMOUNTING
J9505-94
Fig.15AccelerationSwitchPositionIndicator
SPECIFICATIONS
TORQUECHART
BRAKES 5-37
DESCRIPTION TORQUE
AccelerationSensor
SensorBolt.............8-9N-m(71-83in.lbs.)
BracketBolt............1-2N-m(13-18in.lbs.)
HydraulicControlUnit
Mountingbolts............20N-m(177in.lbs.)
BracketMountingbolts...4-9N-m(35-76in.lbs.)
BrakeLines..............16N-m(144in.lbs.)
ControllerAnitlockBrakes
MountingBolts........8-13N-m(75-115in.lbs.)
WheelSpeedSensors
FrontMountingBolt..........4-6(34-50in.lbs.)
RearMountingBolt...12-14N-m(106-124in.lbs.)

74. TJ
page
GENERALINFORMATION
CLUTCHCOMPONENTS....................1
CLUTCHINTERLOCKSAFETYSWITCH
BY-PASS.............................1
INSTALLATIONMETHODSANDPARTS
USAGE...............................1
DESCRIPTIONANDOPERATION
CLUTCHOPERATION.....................2
DIAGNOSISANDTESTING
DIAGNOSTICINFORMATION...............2
SERVICEPROCEDURES
CLUTCHCOMPONENTLUBRICATION........9
GENERAL INFORMATION
CLUTCHCOMPONENTS
TheclutchmechanisminTJmodelsconsistsofa
single,dry-typediscandadiaphragmstyleclutch
cover.Ahydrauliclinkageisusedtooperatethe
clutchreleasebearingandfork.
Aneedle-typepilotbearingsupportsthetransmis-
sioninputshaftinthecrankshaft.Aconventional
releasebearingisusedtoengage'anddisengagethe
clutchcoverpressureplate.
Thereleasebearingisoperatedbyareleaseforkin
theclutchhousing.Theforkpivotsonaballstud
mountedinthehousing.Thereleaseforkisactuated
byahydraulicslavecylindermountedonthehous-
ing.Theslavecylinderisoperatedbyaclutchmaster
cylindermountedonthedashpanel.Thecylinder
pushrodisconnectedtotheclutchpedal.
Theclutchdischascushionspringsinthedisc
hub.Theclutchdiscfacingisrivetedtothehub.The
facingismadefromanon-asbestosmaterial.The
clutchcoverpressureplateisadiaphragmtypewith
aone-piecespringandmultiplereleasefingers.The
pressureplatereleasefingersarepresetduringman-
ufactureandarenotadjustable.
HYDRAULICLINKAGECOMPONENTS
Thehydrauliclinkageconsistsofaclutchmaster
cylinderwithintegralreservoir,a'clutchslavecylin-
derandaninterconnectingfluidline.
Theclutchmastercylinderpushrodisconnected
totheclutchpedal.Theslavecylinderpushrodis
connectedtotheclutchreleasefork.Themastercyl-
inderismountedonthedriversideofthedashpanel
CLUTCH
CONTENTS
CLUTCH6-1
page
CLUTCHFLUIDLEVEL....................9
CLUTCHLINKAGEFLUID..................9
FLYWHEEL.............................9
REMOVALANDINSTALLATION
CLUTCHCOVERANDDISC...............10
CLUTCHHOUSING......................12
CLUTCHHYDRAULICLINKAGE............12
CLUTCHPEDAL........................13
PILOTBEARING........................12
RELEASEBEARING.....................11
SPECIFICATIONS
TORQUE..............................14
adjacenttothebrakemastercylinderandbooster
assembly.Thispositioningissimilarforbothleftand
righthanddrivemodels.
INSTALLATIONMETHODSANDPARTSUSAGE
Distortionofclutchcomponentsduringinstallation
andtheuseofnon-standardcomponentsarecommon
causesofclutchmalfunction.
Improperclutchcoverbolttighteningcandistort
thecover.Theusualresultisclutchgrab,chatter
andrapidwear.Tightenthecoverboltsasdescribed
inRemovalandInstallation.section.
Animproperlyseatedflywheeland/orclutchhous-
ingareadditionalcausesofclutchfailure.Improper
seatingwillproducemisalignmentandadditional
clutchproblems.
Theuseofnon-standardorlowqualitypartswill
alsoleadtoproblemsandwear.Userecommended
factoryqualitypartstoavoidcomebacks.
Acockedpilotbearingisanothercauseofclutch
noise,drag,hardshifting,andrapidbearingwear.
Alwaysuseanalignmenttooltoinstallanewbear-
ing.Thispracticehelpsavoidcockingthebearing
duringinstallation.
CLUTCHINTERLOCKSAFETYSWITCHBY-PASS
WARNING:Thisprocedureisintendedforuseonly
off-road.Whenthevehicleisreturnedtoroaduse,
properlyconnecttheclutchinterlocksafetyswitch.
Dangerousconditionsmayresult.
TheClutchInterlockSafetySwitchwillinhibitthe
startercrankingcircuituntiltheclutchpedalis

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