ABS JEEP CHEROKEE 1994 Service Repair Manual

(5) Support sun gear on wood block (Fig. 6). Then
remove first sun gear snap ring and separate drum
from gear.
(6) Remove remaining snap ring from sun gear
(Fig. 7).
(7) Measure inside diameter of sun gear bushings
with bore gauge or inside micrometer (Fig. 8). Maxi-
mum allowable diameter is 27.08 mm (1.0661 in.).
Replace sun gear if bushing inside diameter is
greater than specified.
SUN GEAR AND CLUTCH ASSEMBLY
(1) Install first snap ring on sun gear.
(2) Install sun gear in drum and install remaining
snap ring.(3) Coat replacement seal rings with petroleum
jelly and install them on sun gear.Be sure seal
ring ends are interlocked.
(4) Install thrust washer. Be sure washer tabs are
seated in drum slots.
(5) Install one-way clutch/second brake hub assem-
bly on sun gear. Deep side of hub flange faces up-
ward (Fig. 9).
(6) Check one-way clutch operation again (Fig. 2).
Hold sun gear and turn second brake hub clockwise
and counterclockwise. Hub should turn clockwise
freely, but lock when turned counterclockwise.
Fig. 2 Checking One-Way Clutch Operation
Fig. 3 Removing/Installing Brake Hub And Clutch
Assembly
Fig. 4 Removing/Installing Thrust Washer
Fig. 5 Removing/Installing Sun Gear Seal Rings
21 - 230 AW-4 TRANSMISSION OVERHAULJ

(3) Compress return springs with shop press and
Compressor Tool 7538. Install piston snap ring and
remove brake assembly from press.
(4) Check brake piston operation with low pressure
compressed air (Fig. 7). Apply air pressure through
feed hole in drum. Piston should move smoothly
when applying-releasing air pressure.
(5) Coat thrust washer with petroleum jelly and
install it in drum. Be sure washer notches are
aligned with tabs on spring retainer (Fig. 8).
(6) Set brake components aside for final assembly.
Fig. 6 Measuring Second Brake Piston Return Springs
Fig. 7 Checking Second Brake Piston Operation
Fig. 8 Installing Second Brake Thrust Washer
Fig. 4 Removing/Installing Second Brake Piston Snap Ring
Fig. 5 Removing/Installing Piston And Sleeve
JAW-4 TRANSMISSION OVERHAUL 21 - 233

(22) Install planetary sun gear and input drum
(Fig. 17). Be sure drum thrust washer tabs are
seated in drum. Use petroleum jelly to hold thrust
washer in position if necessary.
(23) Install front planetary gear on sun gear (Fig.
18).
(24) Support output shaft with wood blocks (Fig.
19).
(25) Install planetary snap ring on sun gear with
snap ring plier tool 7541 (Fig. 20).(26) Install tabbed thrust race on front planetary
gear (Fig. 21). Washer tabs face down and toward
gear. Race outer diameter is 47.8 mm (1.882 in.). In-
side diameter is 34.3 mm (1.350 in.).
(27) Install second coast brake band (Fig. 22).
(28) Install pin in second coast brake band. Then
install retaining ring on pin (Fig. 23).
(29) Install thrust bearing and race in forward-di-
rect clutch (Fig. 24). Coat bearing/race with petro-
leum jelly to hold them in place.
(30) Verify forward-direct clutch thrust bearing
size.
Fig. 17 Installing Sun Gear And Input Drum
Fig. 18 Installing Front Planetary Gear
Fig. 19 Supporting Output Shaft
Fig. 20 Installing Front Planetary Snap Ring
JAW-4 TRANSMISSION OVERHAUL 21 - 259

(87) Install spacer and speedometer drive gear on
output shaft. Then install retaining snap ring (Fig.
64).
(88) Apply bead of Mopar or Loctite 599 sealer to
sealing surface at rear of case (Fig. 65).
(89) Install adapter housing on transmission.
Tighten adapter bolts to 34 Nzm (25 ft. lbs.) torque.
(90) Install transmission speed sensor (Fig. 66).
Tighten sensor bolt to 7.4 Nzm (65 in. lbs.) torque
and connect sensor wire harness connector.
(91) Install converter housing (Fig. 67). Tighten 12
mm diameter housing bolts to 57 Nzm (42 ft. lbs.)
torque. Tighten 10 mm diameter housing bolts to 34
Nzm (25 ft. lbs.) torque.(92) Install transmission shift lever on manual
valve shaft. Do not install lever attaching nut at this
time.
(93) Move transmission shift lever fully rearward.
Then move lever two detent positions forward.
(94) Mount park/neutral position switch on manual
valve shaft and tighten switch adjusting bolt just
enough to keep switch from moving (Fig. 68).
(95) Install park/neutral position switch tabbed
washer and retaining nut (Fig. 68). Tighten nut to
6.9 Nzm (61 in. lbs.) torque, but do not bend any of
the washer tabs against the nut at this time.
(96) Align park/neutral position switch standard
line with groove or flat on manual shaft (Fig. 68).
(97) Tighten park/neutral position switch adjusting
bolt to 13 Nzm (9 ft. lbs.) torque.
(98) Install transmission shift lever on manual
Fig. 66 Installing Transmission Speed Sensor
Fig. 67 Installing Converter Housing
Fig. 64 Installing Spacer And Speedometer Drive
Gear
Fig. 65 Applying Sealer To Case Rear Flange
21 - 270 AW-4 TRANSMISSION OVERHAULJ

(2) Carefully pry the applique off the license plate
visor and tailgate (Fig. 62).
INSTALLATION
(1) Align the moulding with the visor and then
press the applique into place.
(2) Install the rivets to attach the outboard tabs on
applique to the tailgate.
WOODGRAIN OVERLAY
SERVICE INFORMATION
Exterior woodgrain overlay is a weather-resistant
vinyl. The adhesive backing is protected by a paper
liner until removed for installation.
OVERLAY REPAIR
Small nicks and scratches on an overlay can be
touched-up with paint.
To eliminate blisters and air bubbles, pierce them
with a needle or pin. Force the trapped air out of the
hole and press firmly on the overlay. Heat also can
be applied to remove small wrinkles.
Whenever an overlay must be stretched, do
not slit or cut it. Instead, apply heat and press
or squeegee the overlay into place.
INSTALLATION REQUIREMENTS
Overlay replacement requires metal repair and
paint refinish to be completed before the overlay is
installed.
The work area temperature should be between
18ÉC (65ÉF) and 32ÉC (90ÉF).A woodgrain overlay
should not be replaced if the work area temper-
ature is less than 18ÉC (65ÉF).
The following equipment and material are neces-
sary for overlay installation:
²a commercial woodgrain overlay removal solution;
²a commercial adhesive removal solution;
²liquid dish detergent (for wetting solution);
²a mixture of wetting solution;
²a commercial wax and silicone removal solution;
²isopropyl alcohol (rubbing alcohol);
²a squeegee (4 to 5 inches wide, plastic or hard rub-
ber);
²a water bucket and sponge;
²sandpaper (no. 360 or no. 400, wet or dry type);
²a heat gun (or infra-red heat bulb);
²clean wiping rags or paper towels;
²a pair of scissors;
²a needle or pin; and
²a wax pencil.
Using a wetting solution helps the installation of
an overlay. Prepare a solution by mixing two or three
teaspoons of dish detergent with 1 gallon of water.
Do not use soap.
Too much detergent will reduce the effective-
ness of the mixture.
OVERLAY REMOVAL
(1) Remove the adjacent moulding from panel.
(2) Start at one corner and apply heat with a heat
gun. Slowly peel the overlay from the panel (Fig. 63).
WARNING: USE THE WOODGRAIN OVERLAY AND
ADHESIVE REMOVAL SOLUTIONS IN A WELL-VEN-
TILATED AREA ONLY.
(3) A commercial solution can be used for overlay
removal where a heat gun is ineffective.
(4) Remove any adhesive remaining with a com-
mercial solution.
(5) Wipe the panel with a cloth saturated with a
cleaning solution.
OVERLAY INSTALLATION
The panel area that will be covered by the
woodgrain overlay must be scuff sanded and then
cleaned with a cleaning solution.
SURFACE PREPARATION
(1) Scuff-sand the painted surface with no. 360 or
400 sandpaper.Freshly painted surfaces must be
dry.
(2) Clean the painted surface with a commercial
wax and silicone removal solution. Wipe the surface
with a clean cloth and allow it to dry.
OVERLAY PREPARATION
(1) If a complete panel overlay is not to be in-
stalled, position the overlay on the panel surface to
be covered:
²mark the approximate outline on the overlay with
a wax pencil;
Fig. 63 Woodgrain Overlay Removal
23 - 22 BODY COMPONENTSÐXJ VEHICLESJ

(3) Remove the retaining screws at the cowl tabs
and remove the defroster duct from the dash panel
(Fig. 22).(4) Remove the steering column. Refer to the re-
moval procedure in Group 19.
(5) Remove the screws and remove the control ca-
ble and vacuum motor covers from the cowl side and
dash panel (Fig. 23).
(6) Remove the heater and A/C evaporator unit
from the dash panel (Figs. 24 and 25).
(5) Remove the retainers, the push-on nuts and the
insulation panel from the dash panel (Fig. 26).
INSTALLATION
(1) Position the insulation panel on the dash panel
and install the retainers and the push-on nuts (Fig.
26).
(2) Install the heater and A/C evaporator unit on
the dash panel. If necessary, refer to the installation
procedure in Group 24.
(3) Install the steering column.
(4) Position the defroster duct on the cowl tabs and
install screws. Tighten screws to 2 Nzm (20 in-lbs)
torque.
Fig. 20 Courtesy Lamp Support Bracket
Fig. 21 Side window Defroster Tubes
Fig. 22 Defroster Duct Removal/Installation
Fig. 23 Blend-Air and Vacuum Motor Covers
Fig. 24 Heater and A/C Evaporator Unit Retaining
Nuts
23 - 96 BODY COMPONENTSÐXJ VEHICLESJ

(7) Compress the seat cushion and attach the re-
tainer tabs at the front and rear of the cover to the
retainer wire.
(8) With the seat cushion compressed, install the
serrated retainers at the sides of the cover and the
frame edge.
REAR SEATBACKÐXJ VEHICLES
REMOVAL
(1) Disengage the seat cushion at the rear by pull-
ing upward on the release strap.
(2) Tilt the seat cushion forward.
Fig. 84 Seat Cushion Cover On Pad
Fig. 85 Seat Cushion Cover Serrated Retainer
Installation
Fig. 86 Seat Cushion Disengagement At Rear
JBODY COMPONENTSÐXJ VEHICLES 23 - 109

BUFFING AND POLISHING
Minor paint defects in a base/colorcoat can fre-
quently be removed by light sanding, buffing and
polishing. Wet sand the defect with 600 grit paper
soaked in mineral spirits.
Buff the surface area with a fine grade buffing
compound. Finish the repair with a quality polishing
compound to blend and restore the gloss.
BODY UNDERCOAT
Undercoat is applied to the exterior side of wheel-
houses and underbody panels.
PLASTIC COMPONENTS
Plastic components are molded from three different
types of plastic compounds. The three compounds are:
ABS (acrylo-nitrile, butadiene, styrene); polypropy-
lene and vinyl. Minor cracks in any of the three
types can be repaired with 3M 8101 structural adhe-
sive, or an equivalent product.
Fig. 8 Liftgate Basecoat/Clearcoat Paint FinishÐXJ
Vehicles
Fig. 9 Grille Opening Panel, Crossmember and
Baffle Argent Accent Paint
Fig. 10 Body Side Argent Accent Paint Finish
Fig. 11 Front Wheelhouse UndercoatÐXJ Vehicles
Fig. 12 Rear Wheelhouse UndercoatÐXJ Vehicles
JBODY COMPONENTSÐXJ VEHICLES 23 - 203

The three compounds can be identified with a
flame test (Fig. 15). To perform the test, first cut a
small sample of the material from a non-visible por-
tion of the plastic. Then apply an open flame to the
sample and observe the smoke or flame color.
ABS and polypropylene only require an open flame
for testing. However, vinyl must be burned in combi-
nation with copper.
To test vinyl, heat a length of solid copper wire un-
til it is red hot. Immediately apply the hot wire to
the plastic sample until some of the material adheres
to the copper. Then expose the copper wire and sam-
ple to an open flame (Fig. 15).
²ABS material will produce black smoke when
burned.
²Polypropylene will produce little or no smoke.
²Vinyl will produce a blue green flame when
burned in combination with copper.
EXTERIOR BODY COLORS
Exterior vehicle body colors are identified on the
Vehicle Code plate. The plate is located on the left
side of the dash panel in the engine compartment.
The color code location is described in the Introduc-
tion of this manual.
OEM paint colors are generally available from all
of the major paint suppliers. They are supplied in the
form of either mixing formulas or factory packaged
(pre-mixed) paint.
The exterior body and interior trim colors and cor-
responding JeepŸ paint codes are listed in the fol-
lowing charts.
Fig. 15 Plastic Flame Tests
Fig. 13 Underbody Center Section UndercoatÐXJ
Vehicles
Fig. 14 Underbody Rear Section (Above Fuel Tank)
UndercoatÐXJ Vehicles
23 - 204 BODY COMPONENTSÐXJ VEHICLESJ

HEATING AND AIR CONDITIONING
CONTENTS
page page
CLIMATE CONTROL SYSTEMÐXJ VEHICLES . 22
CLIMATE CONTROL SYSTEMÐYJ VEHICLES . 37
COMPRESSOR OVERHAUL............... 17
GENERAL INFORMATION.................. 1SERVICE DIAGNOSISÐELECTRICAL........ 14
SERVICE DIAGNOSISÐMECHANICAL........ 8
TORQUE SPECIFICATIONS................ 45
GENERAL INFORMATION
INDEX
page page
A/C Operation............................ 1
Compressor Oil Level...................... 6
Pressure Gauge and Manifold Assembly........ 2
Refrigerant (R-12)......................... 1
Service Precautions........................ 2Service Valves........................... 3
System Charge........................... 5
System Discharge......................... 4
System Evacuation........................ 4
A/C OPERATION
The compressor increases the pressure and temper-
ature of the refrigerant. The heated refrigerant vapor
is then pumped into the condenser where it cools by
the air passing over the condenser fins. As the refrig-
erant cools in the condenser, it condenses into a liq-
uid. Still under high pressure, the liquid refrigerant
passes into the receiver. The receiver acts as a reser-
voir to furnish refrigerant to the expansion (H) valve
at all times. From the receiver, the high pressure liq-
uid refrigerant passes to the expansion (H) valve.
The expansion (H) valve meters refrigerant into the
evaporator where a low pressure is maintained by
the suction side of the compressor. As it enters the
evaporator, the refrigerant immediately begins to
boil by absorbing heat from the air passing over the
evaporator core. Having given up its heat to boil the
refrigerant, the air is cooled and passes into the pas-
senger compartment of the vehicle. From the evapo-
rator the vaporized refrigerant is drawn back to the
compressor to repeat the cycle.
REFRIGERANT (R-12)
It is illegal to release R-12 into the atmosphere.
SAFETY PRECAUTIONS
WARNING: EXTREME CARE MUST BE TAKEN TO
PREVENT ANY LIQUID REFRIGERANT FROM COM-
ING IN CONTACT WITH THE SKIN AND ESPE-
CIALLY THE EYES. ALWAYS WEAR SAFETYGOGGLES WHEN SERVICING ANY PART OF THE
REFRIGERANT SYSTEM. IF EYE CONTACT IS
MADE, APPLY A FEW DROPS OF MINERAL OIL TO
THE EYES AND FLUSH WITH WATER FOR SEV-
ERAL MINUTES. SEEK MEDICAL ATTENTION IMME-
DIATELY.
The refrigerant used in the air conditioner system
is Refrigerant-12 (R-12). R-12 is nonexplosive, non-
flammable, non-corrosive, has practically no odor and
is heavier than air. Although it is classified as a safe
refrigerant, certain precautions must be observed to
protect the parts involved and the person who is
working on the unit. Liquid R-12, at normal atmo-
sphere pressures and temperatures, evaporates so
quickly that it has the tendency to freeze anything it
contacts.
WARNING: TO AVOID A DANGEROUS EXPLOSION,
NEVER WELD OR STEAM CLEAN NEAR AIR CON-
DITIONING LINES OR COMPONENTS. DO NOT
HEAT R-12 ABOVE 52ÉC (125ÉF).
The R-12 in the system is always under pressure.
Because the system is tightly sealed, heat applied to
any part could cause this pressure to build up exces-
sively.
JHEATING AND AIR CONDITIONING 24 - 1