lock JEEP CHEROKEE 1994 Service Repair Manual

PARKING BRAKE HANDLE COVERÐXJ
VEHICLES
REMOVAL
(1) Detach the rear of the cover from the base and
pivot it upward.
(2) Remove the retaining screws from the cover
base.
(3) Remove the trim cover from the from the floor.
INSTALLATION
(1) Position the cover on the floor and install the
retaining screws.
(2) Pivot the cover to the closed position and en-
gage the locking tab.
MINI-CONSOLE WITH FLOOR SHIFT
REMOVAL
(1) Remove the transmission shift lever handle/
knob. For vehicles with an automatic transmission,
pull the handle straight up. For vehicles with a man-
ual transmission, loosen the locknut and un-thread
the shift knob from the shaft.
(2) Remove the automatic transmission and trans-
fer case shift indicator bezel by prying upward to re-
lease them.
(4) Disconnect the lamp socket from the bezel.
(5) Remove the console retaining screws.
(6) Disconnect the wire harness connector.
(7) Remove the mini-console from the transmission
tunnel.
INSTALLATION
(1) Position the mini-console on the transmission
tunnel, connect the wire harness connector and in-
stall the retaining screws. Tighten the screws to 1
Nzm (13 in-lbs) torque.(2) Position the shift indicator bezel at the console
and connect the lamp socket to the bezel. Install the
bezel in the console.
(3) Install the shift lever handle/knob. For auto-
matic transmissions, push the handle downward un-
til it is engaged. For manual transmissions, thread
the knob onto the shaft and tighten the locknut.
FULL FLOOR CONSOLEÐXJ VEHICLES
REMOVAL
(1) Remove the transmission shift lever handle/
knob. For automatic transmissions, pull the handle
straight upward to remove it. For manual transmis-
sions, loosen the locknut and un-thread the shift
knob from the shaft.
(2) Remove the automatic transmission shift indi-
cator bezel. Remove the transfer case shift indicator
bezel (if equipped) or cover plate from the console.
(3) If equipped, insert a thin-blade tool under the
edge of the outside mirror remote control switch and
pry outward to detach it from the console. Disconnect
the wire harness connector from the switch (Fig.
195).
(4) Remove the cover retaining screws and remove
the cover from the console.
(5) Remove the remainder of the console attaching
screws from the brackets and disconnect the wire
harness connector.
(6) Separate the console floor air duct from the air
outlet duct.
(7) Remove the console and air duct from the floor.
(8) Separate the floor air duct from the console.
(9) Remove the retaining screws and detach the
floor duct from the heater housing, if necessary.
(10) Remove the console support brackets.
The brackets are attached directly to the
floor panel below the carpet.
Fig. 142 Park Brake Cover With Mini-ConsoleÐXJ
Vehicles
Fig. 143 Mini-Console With Floor Shift
JBODY COMPONENTSÐXJ VEHICLES 23 - 125

BODY COMPONENTSÐYJ VEHICLES
CONTENTS
page page
ADD-A-TRUNK........................ 198
DOORS.............................. 172
EXTERIOR COMPONENTS............... 134FIXED WINDOW GLASS................ 181
GENERAL SERVICE INFORMATION........ 132
INTERIOR COMPONENTS............... 188
GENERAL SERVICE INFORMATION
LABELS/DECALS/PLATES
Most of the labels, decals and metal plates that are
affixed to YJ vehicles (Figs. 1, 2, 3, 4 and 5) contain
either safety or otherwise essential information.
Refer to the Introduction of this manual for addi-
tional information involving labels and metal plates.
INSTALLATION
Follow the instructions included with each replace-
ment label/decal/plate to affix it to a panel, compo-
nent or window glass.
KEY LOCK CYLINDERS
The ignition switch, glove box door, floor console,
metal front doors and the tailgate all have key lock
cylinders. When lock cylinder service is necessary,
refer to the applicable service information source:
²Ignition SwitchÐGroup 8D,
²Instrument Panel,
²Floor Consoles,
²Front Doors, and
²Tailgate.
Fig. 1 YJ Underhood Labels/DecalsFig. 2 YJ Interior and License Plate Holder Labels/
Decals
23 - 132 BODY COMPONENTSÐXJ VEHICLESJ

EXTERIOR COMPONENTS
INDEX
page page
Battery Tray........................... 140
Body Extension Panels and FasciasÐYJ
Renegade Vehicles..................... 147
Body Side Step Moulding................. 145
Body Stripes/Decals..................... 153
Cowl Grille and Screen................... 139
Cowl Weatherstrip Seal................... 139
Exterior Nameplates (Adhesive-Backed)....... 158
External Spare/Wheel Tire Carrier........... 172
Fender Flare........................... 144
Fender Inner Splash Shields............... 147
Fender Splash Aprons.................... 147
Fenders............................... 141
Fog LampÐYJ Renegade Vehicles.......... 150
Front Fascia and Skid PlateÐYJ Renegade
Vehicles............................. 148
Front Fender Extension PanelÐYJ Renegade
Vehicles............................. 149
Fuel Filler Protector/Nozzle................ 158
Half Metal Door Mirror (External)............ 158
Hard Top Liftgate Glass.................. 162
Hard Top Repair........................ 165
Hard Top Roof Vent..................... 165
Hard Top Service....................... 164
Hard Top Service Information.............. 164Hood................................. 137
Hood Alignment......................... 138
Hood Insulator Panel..................... 138
Hood Safety Latch....................... 139
Liftgate Glass Weatherstrip Seal Replacement . . 163
Radiator Grille Applique................... 134
Rear Fascia and Skid PlateÐYJ Renegade
Vehicles............................. 152
Rear Quarter Extension PanelÐYJ Renegade
Vehicles............................. 151
Rocker Extension PanelÐYJ Renegade
Vehicles............................. 150
Soft Top Service........................ 167
Soft Top Service Information............... 166
Sport Bar............................. 171
Tailgate Adjustment...................... 160
Tailgate Hinge.......................... 159
Tailgate Latch and Release Handle.......... 160
Tailgate Latch Striker..................... 161
Tailgate Lock Cylinder.................... 160
Tailgate Service......................... 159
Tailgate Service Information................ 159
Tailgate Weatherstrip Seal................. 161
Wheelhouse Splash Liners................ 146
RADIATOR GRILLE APPLIQUE
REMOVAL
(1) Raise the hood.
(2) Remove the headlamp bezels (Fig. 1).
(3) Remove the headlamp bulb retainer screws
(Fig. 2).
(4) Disconnect and remove the headlamps and
buckets as a unit (Fig. 2).
(5) Remove the parking lamp retaining screws
(Fig. 2).
(6) Disconnect the wire harness connectors and re-
move the parking lamps (Fig. 2).
(7) Remove the front crossmember cover.
(8) Remove the retaining screws and the bumper
inserts at the top of the grille panel (Fig. 1).
(9) Detach the grille applique from the grille panel
(Fig. 1).
(10) Remove the double faced foam adhesive tape
at the bottom of the grille applique (Fig. 1).
INSTALLATION
(1) Install double faced foam tape at the bottom,
interior side of the grille applique (Fig. 1).
(2) Position the grille applique over the grille
panel and press inward along the bottom where the
tape is located (Fig. 1).
(3) Install the grille applique retaining screws and
the bumper inserts (Fig. 1).(4) Connect the wire harness connectors and posi-
tion the headlamp buckets and headlamps in the
grille panel (Fig. 2).
(5) Install the headlamp bulb retainer and the
screws (Fig. 1). Tighten the screws to 2 Nzm (18 in-
lbs) torque.
(6) Install the headlamp bezels and the retaining
screws (Fig. 1). Tighten the screws securely.
(7) Connect the wire harness connectors and in-
stall the parking lamps (Fig. 2).
(8) Install the parking lamp retaining screws.
Tighten the screws to 2 Nzm (18 in-lbs) torque.
(9) Close the hood.
(10) Install the front crossmember cover.
23 - 134 BODY COMPONENTSÐXJ VEHICLESJ

(2) Remove the mirror from the door hinge (Fig.
78).
INSTALLATION
(1) Clean the door hinge-mirror base contact sur-
face.
(2) Position the mirror base at the door hinge (Fig.
78).
(3) Install the mirror base attaching screws in the
door hinge (Fig. 78). Tighten the attaching screws to
11 Nzm (96 in-lbs) torque.
TAILGATE SERVICE INFORMATION
The following tailgate service procedures include:
²tailgate removal/installation,
²tailgate hinge replacement,
²tailgate adjustment,
²tailgate latch removal/installation,
²tailgate lock cylinder removal/installation,
²tailgate latch striker removal/installation, and
²tailgate seal replacement.
TAILGATE SERVICE
REMOVAL
(1) For YJ Renegade vehicles:
²open the tailgate;
²remove the tailgate check rod cover by removing
the screws located at the outer edge of the cover (Fig.
80);
²use a small pry bar to pry out the rod spacer that
retains the check rod in the bracket (Fig. 81);²apply inward pressure on the rod to release it from
the bracket (Fig. 81);
²remove the check rod from the tailgate;
²remove the plastic shield from the tailgate (Fig.
81); and
²close the tailgate.
(2) For all vehicles, remove the tailgate hinge
screws with a Torx bit (Fig. 82).
(3) Disengage the latch and remove the tailgate
from the vehicle.
INSTALLATION
(1) Position and align the tailgate in the body
opening and engage the latch.
(2) Install the hinge retaining screws (Fig. 82).
Tighten the screws to 18 Nzm (156 in-lbs) torque.
(3) For YJ Renegade vehicles, install the shield,
check rod and spacer (Figs. 81 and 82). Tighten the
slide pin to 75 Nzm (55 ft-lbs) torque.
(4) For YJ Renegade vehicles, install the check rod
cover (Figs. 80 and 82). Tighten the screws to 3 Nzm
(24 in-lbs) torque.
TAILGATE HINGE
REPLACEMENT
(1) Remove the hinge retaining screws and remove
the hinge (Fig. 82).
(2) Prepare and paint the replacement hinge to
match the body paint color.
(3) Lubricate the hinge with spray lubricant.
(4) Position the hinge on the body and install the
retaining screws (Fig. 82). Tighten the screws to 18
Nzm (156 in-lbs) torque.
Fig. 80 Check Rod Cover
Removal/InstallationÐRenegade Vehicles
Fig. 81 Check Rod Spacer RemovalÐRenegade
Vehicles
JBODY COMPONENTSÐXJ VEHICLES 23 - 159

(5) Align the tailgate with the hinge and install
the hinge-to-tailgate screws (Fig. 82). Tighten the
screws to 18 Nzm (156 in-lbs) torque.
TAILGATE ADJUSTMENT
(1) Loosen the tailgate hinge-to-body screws (Fig.
82).
(2) Align the tailgate in the body opening and
tighten the hinge screws to 18 Nzm (156 in-lbs)
torque (Fig. 82).
TAILGATE LATCH AND RELEASE HANDLE
REMOVAL
(1) Open the tailgate and remove the latch trim
cover (Fig. 82).
(2) Remove the tailgate latch-to-handle rod re-
tainer and disconnect the rod from the latch (Fig.
82).
(3) Remove the latch-to-tailgate screws (Fig. 82).
(4) Remove the retainer clip from the latch-to-lock
cylinder rod and disconnect the rod from the lock cyl-
inder (Fig. 83).
(5) Remove the retainer clip from the latch-to-re-
lease handle rod and disconnect the rod from the re-
lease handle (Fig. 83).
(6) Remove the latch from the tailgate (Fig. 82).
(7) Remove the latch release handle screws (Fig.
82).
(8) Remove the release handle and seal from the
tailgate (Fig. 82).
INSTALLATION
(1) Position seal latch release handle on the tail-
gate and install screws (Fig. 82). Tighten the screws
to6Nzm (50 in-lbs) torque.
(2) Position the latch at the tailgate (Fig. 82).
(3) Install the latch retaining screws and connect
the latch rods and rod retainers (Figs. 83 and 84).
Tighten the screws to 6 Nzm (50 in-lbs) torque.
(4) Install the latch cover (Fig. 82). Tighten the
screws to 11 Nzm (96 in-lbs) torque.
TAILGATE LOCK CYLINDER
REMOVAL
(1) Open the tailgate.
(2) Remove the latch cover (Fig. 82).
(3) Remove the lock cylinder retainer clip (Fig. 85).
Fig. 82 Tailgate and Components
Fig. 83 Tailgate Latch and Rods
23 - 160 BODY COMPONENTSÐXJ VEHICLESJ

(4) Disengage the lock cylinder lever (Fig. 85) from
the latch-to-lock cylinder rod.
(5) Remove the lock cylinder from the tailgate
opening.
(6) Remove the E-clip and separate the lever from
the lock cylinder (Fig. 85).
INSTALLATION
(1) Inspect the retainer clip and the gasket. As ap-
plicable, replace if distorted or damaged.
(2) Attach the lever to the lock cylinder with the
E-clip and position the lock cylinder in the tailgate
opening (Fig. 85).
(3) Connect the latch-to-lock cylinder rod to the le-
ver.
(4) Install the lock cylinder retainer clip (Fig. 85).(5) Install the latch cover (Fig. 82). Tighten the
screws to 11 Nzm (96 in-lbs) torque.
TAILGATE LATCH STRIKER
REMOVAL
(1) Remove the striker from the bracket with a
Torx bit (Fig. 86).
(2) Remove the plate, shim and washer from the
bracket (Fig. 86).
(3) Remove the retaining screws and the striker
bracket from the tailgate reinforcement bracket (Fig.
86).
INSTALLATION
(1) Position the striker bracket on the tailgate and
install the retaining screws in the reinforcement
bracket (Fig. 86). Tighten the screws to 11 Nzm (96
in-lbs) torque.
(2) Position the washer, shim and plate on the
striker bracket (Fig. 86).
(3) Install the striker in the bracket with a Torx
bit (Fig. 86). Tighten the striker to 71 Nzm (52 ft-lbs)
torque while retaining the striker plate in-place.
TAILGATE WEATHERSTRIP SEAL
REMOVAL
(1) Remove the seal retaining rivets (Fig. 87).
(2) Carefully separate the seal and the retainers
from the tailgate edge (Fig. 87).
(3) If the original seal will be installed, clean it
with a dampened cloth.
(4) Clean the seal contact surface on the tailgate
(Fig. 87).
(5) Inspect the seal and retainers (Fig. 87). Replace
the seal if damaged.
Fig. 84 Tailgate Latch Installation
Fig. 85 Tailgate Lock Cylinder Removal/Installation
Fig. 86 Tailgate Latch Striker Removal/Installation
JBODY COMPONENTSÐXJ VEHICLES 23 - 161

SOFT TOP SERVICE
REMOVAL
(1) Detach the snap-on retainers from the upper
side retainers (Figs. 96 and 98).
(2) Slide the upper side retainer lock forward.
Next, disengage the lock from the pin and remove
the retainer from the door flange (Figs. 96, 97 and
99).
(3) Detach the snap-on retainer at the front corner
(Fig. 100, turn the retainers and remove the door
windows (Fig. 101).
Fig. 97 Soft Top Bow, Spreader Bar and Retainers
Fig. 98 Upper Side Retainers
Fig. 99 Upper Side Retainer Removal From Door
Flange
Fig. 100 Door Window Snap-On Retainer
JBODY COMPONENTSÐXJ VEHICLES 23 - 167

(4) Open the side curtain upper and rear zippers
(Figs. 96 and 102).
(5) Detach the interior snap-on retainer and tab,
and pull the bottom edge of each side curtain out of
the lower side retainer channel (Fig. 103).
(6) Slide the front edge of the side curtain down-
ward and remove it from the center bow retainer
channel (Figs. 96 and 104).
(7) Pull downward on the spreader bar to release
the lock and the tension on the center and rear bows
(Figs. 97 and 105).
(8) Open the tailgate.(9) Open the rear curtain upper and side zippers
(Fig. 106).
(10) Roll up the rear curtain and attach it to the
top cover with the elastic straps and snap-on retain-
ers (Fig. 107).
(11) Pull the bottom edge of the rear corners out-
ward and detach from the side (lower) retainer (Fig.
108).
Fig. 101 Door Window Removal/Installation
Fig. 102 Side Curtain Zippers
Fig. 103 Side Curtain and Lower Side Retainer
Fig. 104 Side Curtain Removal/Installation
23 - 168 BODY COMPONENTSÐXJ VEHICLESJ

(4) Position front of the upper side snap retainers
at the door flanges and lock pin at each side of the
vehicle (Fig. 116). Engage the locks with the pins
and then slide the locks rearward.
(5) Insert the front edge of the top cover into the
retainer channel on the windshield frame (Figs. 110
and 117).
(6) Ensure that the center bow leg is positioned all
the way forward in the receptacle.
(7) Ensure that the rear corners of the top cover
are inserted in the retainer channels (Fig. 117).
(8) Pull the rear bow legs rearward until they en-
gage with the notch in the lower side retainers. En-
sure that the side curtain rear zippers are not
entrapped or folded behind the rear bow.(9) Force the spreader bars (Fig. 118) upward until
the lock engages.
(10) Slide the front edge of each side curtain up-
ward into the retainer channel on the center bow
(Figs. 104 and 117).
(11) Close top zipper on each side curtain5-8cm
(2 - 3 in). Next, close the rear zipper at the bottom
corner of the curtain5-8cm(2-3in).
(12) Attach the side curtain front and rear tab
snap-on retainers to the lower side retainer (Fig.
103).
(13) Completely close both side curtain zippers.
(14) Pull downward firmly on the side curtains.
Start at one end and move toward the opposite end.
The bottom edge of the curtains must be completely
inserted in the lower side retainer channels (Fig.
103).
(15) Release the rear window curtain straps and
insert the bottom edge into the tailgate retainer
channel (Fig. 117). Close the rear window curtain
zippers and attach the side snap-on retainers.
(16) Attach all the top cover snap-on retainers to
the upper side retainers located above both doors
(Fig. 109). As necessary, slide the mating half of the
snap-on retainers so that they will align with the
snap-on retainers on the top cover. Tuck the edge of
the top cover inside the side retainer.
(17) Install the door windows by inserting the re-
tainers into the door grommets. Attach the snap-on
retainers located along the bottom edge of the win-
dow to the door retainer (Fig. 100).
SPORT BAR
REMOVAL
(1) Remove the screws that attach the sport bar
base plates to the floor and wheelhouse panels (Fig.
119).
Fig. 116 Upper Side Retainer Lock Engagement
Fig. 117 Soft Top Installation
Fig. 118 Engaging Spreader Bar Lock
JBODY COMPONENTSÐXJ VEHICLES 23 - 171

(2) Remove the retaining screws and bolts, and re-
move the side bars from the windshield frame and
the sport bar (Figs. 119 and 120).
(3) Carefully lift the sport bar upward (Fig. 119)
and remove it from the vehicle.
(4) If necessary, remove the pads and covers from
the sport bar (Figs. 119 and 120)
INSTALLATION
(1) Clean the base plate contact surface areas on
the floor and wheelhouse panels.
(2) Apply epoxy chromate primer to the attaching
screw hole edges for protection against corrosion.
(3) Position the sport bar base plates on the floor
and wheelhouse panels with the screw holes aligned
(Fig. 119).To prevent water seepage, apply 3M Drip-
Chek Sealant (or an equivalent product) to the
underside of all the screw heads before instal-
lation.
(4) Apply sealant to the underside of each base
plate attaching screw head. Install and tighten the
screws securely (Fig. 119).
(5) Position the side bars at the windshield frame
and at the sport bar (Fig. 119). Install screws and
bolts in the windshield frame and the sport bar (Fig.
120). Tighten the screws securely.
EXTERNAL SPARE/WHEEL TIRE CARRIER
REMOVAL
(1) Remove the spare tire and wheel from the
wheel bracket (Fig. 121).
(2) Remove the screws that attach the wheel
bracket to the tailgate (Fig. 121).
(3) Remove the bracket and the gaskets from the
tailgate (Fig. 121).
(4) Remove the screws that attach the stop bracket
to the rear panel and the bumpers to the tailgate
(Fig. 121).
(5) Remove the stop bracket and the bumpers from
the vehicle (Fig. 121).
(6) Clean the contact surface areas on the tailgate
and the rear panel.
INSTALLATION
(1) Position the stop bracket and the bumpers on
the vehicle (Fig. 121) and install screws. Tighten the
screws to 11 Nzm (95 in-lbs) torque.
(2) Position the gaskets and the wheel bracket on
the tailgate and install the attaching screws (Fig.
121). Tighten the screws to 23 Nzm (204 in-lbs)
torque.
(3) Install the spare tire and wheel on the wheel
bracket (Fig. 121). Tighten the wheel lug nuts and
the nut lock to 68 Nzm (50 ft-lbs) torque.
Fig. 119 Sport Bar
Fig. 120 Sport Bar-To-Side Bar Bolt
Fig. 121 External Spare Tire/Wheel Carrier
23 - 172 BODY COMPONENTSÐXJ VEHICLESJ