key JEEP CHEROKEE 1994 Service Manual Online

(33 in. lbs.) torque. Thread the hazard warning
switch knob into the switch and pull the knob out-
ward.
(38) Install and seat the upper bearing race in the
key/lock cylinder housing.
(39) Install the upper bearing preload spring, the
canceling cam and the lockplate.
(40) Install a replacement lockplate retaining snap
ring on the sleeve of the Lock Plate Compressor
C-4156 (J-23653-B). Install the tool on the steering
shaft (Fig. 24).(41) Compress the lockplate with the compressor
tool and position the retaining snap ring in the steer-
ing shaft groove.
(42) Remove the compressor tool. Ensure that the
retaining ring is completely seated in the groove be-
fore removing the tool.
(43) Position the wire harness protectors if
equipped, over the harnesses and snap in place on
steering column.
(44) Install the lockplate cover.
(45) Install the gear selector lever and the retain-
ing pin.
(46) Install the steering wheel. Refer to the instal-
lation procedure.
(47) Insert the ignition key in the key/lock cylin-
der; turn the cylinder to the OFF-UNLOCK position;
move the ignition switch downward to eliminate any
switch-to-remote rod lash; and tighten the ignition
switch attaching screws to 4 Nzm (35 in. lbs.) torque.
(48) Depress the dimmer switch slightly and insert
a 3/32-inch drill bit into the adjustment hole.
(49) Loosen the retaining screws and move the
dimmer switch toward the steering wheel. Tighten
the dimmer switch retaining screws to 4 Nzm (35 in.
lbs.) torque.
(50) Remove the drill bit and test operation by
moving the dimmer switch stalk. Test the dimmer
switch operation in the full-up, down and center
steering wheel positions.
(51) Install the steering column, if applicable. Re-
fer to the installation procedure.
CONSOLE SHIFT ASSEMBLY
(1) Position the key-release lever spring on the le-
ver and install the lever with the spring in the
shroud.
(2) Align and install the shroud on the steering
column jacket.
(3) Install the retainer plate. Tilt the plate toward
the 12 o'clock position, slide it under the steering col-
umn jacket opening, and seat it in the jacket notches.
(4) Align the steering column jacket V-notch with
the correspondingVon the support. Install the sup-
port in the steering column. To completely seat the
support, press the key-release lever downward while
pressing the support into place (Fig. 25).
(5) Install all the support retaining screws finger-
tight. Next, tighten the screws alternately and evenly
to7Nzm (60 in. lbs.) torque.
(6) Install the remote rod in the support. Route the
rod through the upper end of the shroud and insert it
into the rod slot located in the support.
(7) Install the dimmer switch and the ignition
switch.
(8) Install the steering shaft in the steering col-
umn.
Fig. 23 Key/Lock Cylinder Installation
Fig. 24 Lockplate Retaining Ring Installation
19 - 66 STEERINGJ

(9) Install replacement races and bearings in the
key/lock cylinder, if removed.Ensure that the bear-
ings are lubricated with chassis lubricant be-
fore installation.
(10) Install the lock shoes, the lock shoe springs
and the lock shoe pin the key/lock cylinder housing.
Use a 4.5-mm (0.18-in) diameter rod to align the
shoes and the pin during installation.
(11) Install the tilt-release lever, the lever spring
and the lever pin in the key/lock cylinder housing.
Insert a wedge between the housing and the lever to
relieve the spring tension. This will allow easier re-
lease lever pin installation.
(12) Install the lock bolt in the key/lock cylinder
housing and engage it in the lock sector cam surface.
(13) Install the lock rack, the rack preload spring
and a replacement shim in the key/lock cylinder
housing. The square block tooth on the lock rack and
lock sector must mate.
(14) Install the lock spring and the spring retain-
ing screw. Tighten the screw to 4 Nzm (35 in. lbs.)
torque.
(15) Align and install the assembled key/lock cylin-
der housing on the support. Retain the lock shoes in
the disengaged position for easier housing installa-
tion.
(16) Align the pivot pin holes in the key/lock cylin-
der housing with those in the support and insert the
pivot pins.Press the housing firmly downward
when inserting the pivot pins to prevent dam-
aging the holes in the support.When the pivot
pins are within both the housing and the support
holes, seat them fully with a punch and a hammer.(17) Insert the tilt-release lever in the key/lock cyl-
inder housing and place the housing in the full-up-
ward tilt position.
(18) Lubricate tilt spring guide and tilt spring lib-
erally with chassis lubricant. Then position spring on
guide.
(19) Insert the tilt spring guide and the spring into
the key/lock cylinder housing. Install the guide re-
tainer over the spring. Engage the retainer lock tabs
with the housing lugs by pressing the retainer down-
ward and turning clockwise with a screwdriver.
(20) Place the cover on the key/lock cylinder hous-
ing. Align and install the cover retaining screws.
Tighten the screws to 7 Nzm (60 in. lbs.) torque.
(21) Route the dimmer switch wire harness down
through the steering column.
(22) To install ignition switch lock, turn the key to
the LOCK position and remove the key. This will
cause the buzzer operating lever to retract in the
key/lock cylinder. Now insert the key/lock cylinder
into the housing far enough to contact the drive
shaft. Force it inward and move the ignition switch
actuator rod up and down to align the components.
When the components align, the key/lock cylinder
will move inward and the spring-loaded retainer will
snap and lock it in place (Fig. 26).
(23) Insert the ignition key in the cylinder and
turn it to the ON position. Install the key warning
buzzer switch.
(24) Install the turn signal switch. Fold the wires
against the connector. Route the wire harness and
connector down through the steering column. Posi-
tion the switch in the key/lock cylinder housing.Do
notinstall the switch retaining screws at this time.
Fig. 26 Key/Lock Cylinder
Fig. 25 Steering Column Support Installation
JSTEERING 19 - 67

(25) Install the windshield wiper wire harness and
switch. Route the wire harness down through steer-
ing column jacket.
(26) If equipped, install the cruise control wire har-
ness. Install the turn signal stalk by pushing it
straight into the column.
(27) Insert the hazard warning knob in the hazard
warning switch and press it inward. Align and install
the turn signal switch retaining screws. Ensure that
the turn signal switch is properly seated before tight-
ening the screws. Tighten the screws to 4 Nzm (33 in.
lbs.) torque. Thread the hazard warning switch knob
into the switch and pull the knob outward.
(28) Install and seat the upper bearing race in the
key/lock cylinder housing.
(29) Install the upper bearing preload spring, the
canceling cam and the lockplate.
(30) Install a replacement lockplate retaining snap
ring on the sleeve of the Lock Plate Compressor C-
4156 (J-23653-B). Install the tool on the steering
shaft (Fig. 27).
(31) Compress the lockplate with the compressor
tool and position the retaining snap ring in the steer-
ing shaft groove.
(32) Remove the compressor tool. Ensure that the
retaining ring is completely seated in the groove be-
fore removing the tool.
(33) Position the wire harness protectors, if
equipped, over the wire harnesses and snap them in
place on the steering column.
(34) Install the lockplate cover.
(35) Install the steering wheel. Refer to the instal-
lation procedure.
(36) Insert the ignition key in the key/lock cylin-
der; turn the cylinder to the OFF-UNLOCK position ;
move the ignition switch downward to eliminateany switch-to-remote rod lash; and tighten the igni-
tion switch attaching screws to 4 Nzm (35 in. lbs.)
torque.
(37) Depress the dimmer switch slightly and insert
a 3/32-inch drill bit into the adjustment hole.
(38) Loosen the retaining screws and move the
dimmer switch toward the steering wheel to remove
any lash. Tighten the dimmer switch retaining
screws to 4 Nzm (35 in. lbs.) torque.
(39) Remove the drill bit and test operation by
moving the dimmer switch stalk. Test the dimmer
switch operation in the full-up, down and center
steering wheel positions.
(40) Install the steering column and steering
wheel. Refer to the installation procedure.
(41) Connect the battery negative cable.
Fig. 27 Lockplate Retaining Ring Installation
19 - 68 STEERINGJ

(2) Secure front bearing with thickest snap ring
that will fit in groove (Fig. 50).
(3) Press front bearing on counter gear. Secure
bearing with thickest snap ring that will fit in ring
groove (Fig. 51).
(4) Install new oil seals in front bearing retainer
and adapter (Fig. 52). Bearing retainer seal depth is
11.2 - 12.1 mm (0.441 - 0.480 in.).(5) Install reverse shaft and shaft retaining pin in
adapter. Then install access hole plug with torx bit
(Fig. 53).
(6) Lubricate transmission components with speci-
fied gear lubricant.
(7) Assemble 1-2 and 3-4 synchronizer hubs,
sleeves, springs and key inserts (Fig. 54).
Fig. 51 Installing Counter Gear Front Bearing And Snap Ring
Fig. 52 Oil Seal Installation
Fig. 53 Installing Reverse Shaft Pin
Fig. 54 Synchronizer Identification
21 - 16 AX 4/5 MANUAL TRANSMISSIONJ

(7) Remove converter housing bolts and remove
housing (Fig. 3) from case.
(8) Remove adapter housing.
(9) Remove speedometer drive gear snap ring and
remove gear and gear spacer if equipped (Fig. 4).(10) Remove speed sensor rotor and key. Use wood
dowel or hammer handle to loosen and remove rotor
(Fig. 5).
(11) Remove transmission oil pan, oil screen and
screen gaskets (Fig. 6). Then mount transmission in
holding fixture.
Fig. 3 Removing/Installing Converter Housing
Fig. 4 Removing Speed Sensor And Speedometer
Drive Gear
Fig. 5 Removing Transmission Speed Sensor Rotor
Fig. 6 Removing Oil Screen
JAW-4 TRANSMISSION OVERHAUL 21 - 193

(82) Install valve body oil tubes (Fig. 62). Tap
tubes into place with a plastic mallet. Be sure the
flanged tube ends and straight tube ends are in-
stalled as shown.
(83) Install new gaskets on oil screen and install
screen on valve body. Tighten screen bolts to 10 Nzm
(7 ft. lbs.) torque.
(84) Install magnet in oil pan. Be sure magnet
does not interfere with valve body oil tubes.
(85) Apply Mopar or Loctite 599 to sealing surface
of oil pan. Sealer bead should be at least 3 mm (1/8
in.) wide. Install pan on case and tighten pan bolts to
7Nzm (65 in. lbs.) torque.
(86) Install transmission speed sensor rotor and
key on output shaft (Fig. 63).
Fig. 63 Installing Transmission Speed Sensor Rotor
And Key
Fig. 61 Connecting Valve Body Solenoid Wires
Fig. 62 Installing Valve Body Oil Tubes
Fig. 59 Aligning Manual Valve, Shift Sector And
Detent Spring
Fig. 60 Connecting Transmission Throttle Cable
JAW-4 TRANSMISSION OVERHAUL 21 - 269

KEY LOCK CYLINDERS
The ignition switch, glove box door, front doors and
liftgate all have key lock cylinders (Fig. 6). When
lock cylinder access or replacement is necessary, re-
fer to the applicable service information source:
²Ignition SwitchÐGroup 8D,
²Instrument Panel,
²Front Doors, and
²Liftgate.
Fig. 4 XJ VIN PlateFig. 5 XJ Jack Usage & Storage Instruction Labels
Fig. 6 Ignition Switch & Glove Box Door Key Lock
Cylinders
23 - 2 BODY COMPONENTSÐXJ VEHICLESJ

DOORS
INDEX
page page
Door Alignment AdjustmentÐMajor........... 47
Door Alignment AdjustmentÐMinor........... 46
Door Edge Guard/Edge Protector Strip........ 61
Door External Handle..................... 55
Door Hinge/Hinge Pin Replacement........... 58
Door Inside Latch Release and Lock Rods..... 57
Door Key Lock Cylinder................... 54
Door Latch............................. 56
Door Latch Adjustment.................... 55
Door Removal/Installation.................. 40
Door Restraint Replacement................ 47
Door Trim Panel......................... 35
Door Window Exterior Mouldings............. 61
Door Window Glass and Door Opening
Weatherstrip Seals...................... 62
Front Door Spacer BlocksÐTwo-Door Vehicles . . 60
Front Door Vent Window................... 50
Front Door Window Glass.................. 49Front Door Window Glass Regulator.......... 48
Liftgate Adjustment....................... 70
Liftgate Hinge........................... 67
Liftgate Latch/Key Lock Cylinder/Striker........ 68
Liftgate License Plate Lamp Housing.......... 72
Liftgate License Plate Screw Anchor and Bumper . 72
Liftgate Opening Weatherstrip Seal........... 70
Liftgate Removal/Installation................ 65
Liftgate Service InformationÐXJ Vehicles...... 65
Liftgate Support Rod Ball Stud Replacement.... 70
Liftgate Support Rod Cylinder............... 69
Liftgate Support Rod Cylinder Disposal........ 70
Liftgate Trim Panel....................... 66
Rear Door Fixed Window Glass............. 53
Rear Door Window Glass.................. 52
Rear Door Window Glass Regulator.......... 51
Service Information....................... 34
SERVICE INFORMATION
The door service procedures includes removal, in-
stallation and/or replacement of the following door
components:
²door handles,
²armrests,²trim panels,
²waterdams,
²door restraints,
²front doors,
²rear doors (XJ vehicles only),
²window glass regulators,
Fig. 1 Front Door Trim Panel
23 - 34 BODY COMPONENTSÐXJ VEHICLESJ

²door vent and window glass,
²key lock cylinders,
²door half-hinges,
²liftgate (XJ vehicles only),
²liftgate hinges (XJ vehicles only),
²
liftgate gas support rod cylinders (XJ vehicles only),
²rocker panel seals, and
²mouldings/weatherstrip seals.
DOOR TRIM PANEL
SERVICE INFORMATION
All attached components can be removed from door
trim panels (Figs. 1 and 2).
REMOVAL
(1) Remove the door inside latch release handle
screws (Figs. 3 and 4).
(2) Move the door handle outward and disconnect
the handle-to-latch rods (Fig. 5). For vehicles
equipped with power door locks/windows, disconnect
the wire harness connector (Fig. 6).
(3) Remove the regulator handle (Fig. 7) or, if
equipped, power window switches and bezel.
(4) Remove the armrest lower screws.
(5) Pull armrest straight outward from panel and
remove the bezel.
Fig. 2 Rear Door Trim Panel
Fig. 3 Front Door Inside Latch Release Handle
Fig. 4 Rear Door Inside Latch Release Handle
JBODY COMPONENTSÐXJ VEHICLES 23 - 35

(2) Pry the window beltline moulding away from
the clips and remove the moulding from the door.
(3) Remove the window weatherstrip seals from
the door.
(4) Remove the trim panel and waterdam from
door inner panel.
(5) Remove the channel/division bar screws. Drill
out the rivet head to remove it from the inner panel.
(6) Tilt the channel/division bar forward and re-
move it from the door.
(7) Remove the fixed glass support bracket bolts
from the door inner panel reinforcement bracket
(Fig. 66).
(8) Remove the fixed glass from the door (Fig. 67).
INSTALLATION
(1) Install the fixed glass in the door, and install
the bolts in the reinforcement and support brackets.
(2) Tighten the bracket retaining bolts to 9 Nzm
(79 in-lbs) torque.
(3) Install the channel/division bar in the door.
(4) Install the channel/division bar screws and
rivet. Tighten the screws to 6 Nzm (5 ft-lbs) torque.
(5) Install the channel and belt weatherstrip seals.
(6) Install the beltline moulding.
(7) Install the door waterdam and trim panel.
DOOR KEY LOCK CYLINDER
REMOVAL
(1) Remove the door trim panel and waterdam.
(2) Disconnect the door latch-to-lock cylinder rod at
the door latch (Fig. 68).
Fig. 67 Fixed Glass Removal/Installation
Fig. 65 Belt Weatherstrip Seals
Fig. 66 Fixed Glass Support Bracket Bolts
Fig. 68 Key Lock Cylinder and Door Latch
23 - 54 BODY COMPONENTSÐXJ VEHICLESJ