light JEEP CHEROKEE 1994 Service Repair Manual

ROUTINE SERVICE
The following routine vehicle service is highly rec-
ommended on a monthly basis.
TIRESÐInspect the tires for unusual wear/damage
and determine if the inflation pressure is acceptable
for the vehicle load.
BATTERYÐInspect and clean the terminals.
Tighten the terminals, if necessary.
FLUIDSÐDetermine if the coolant, brake fluid,
power steering, automatic transmission, and clutch
fluid level are acceptable. Add fluid, if necessary.
LIGHTS/ELECTRICALÐTest all the electrically
operated systems in the vehicle for proper operation.
It is also recommended that the engine oil level
and the windshield washer fluid level be deter-
mined (and corrected) during each fuel fill-up.
FUEL REQUIREMENTS
All Jeeptengines require the use of unleaded gas-
oline. In addition, the fuel must have a minimum oc-
tane rating of 87.
CAUTION: UNLEADED FUEL ONLY must be used in
vehicles equipped with a catalyst emission control
system. All vehicles have reminders printed on the
instrument panel (Fig. 1) and on the fuel filler door
(Fig. 2). Vehicles also have fuel filler tubes that are
designed to accept only the small-diameter un-
leaded gasoline nozzles. It is illegal to defeat the
design of an unleaded fuel filler tube.
CLASSIFICATION OF LUBRICANTS
Lubricating fluids and chassis component lubri-
cants are classified and graded according to stan-
dards recommended by the:
²Society of Automotive Engineers (SAE),²American Petroleum Institute (API), and
²National Lubricating Grease Institute (NLGI).
ENGINE OIL
SAE VISCOSITY GRADE
An SAE viscosity grade is used to specify viscosity
of engine oil. SAE 30 specifies a single viscosity en-
gine oil. Engine oils also have multiple viscosities
(Fig. 3).
The viscosity grade of an oil is an indicator of its
thickness or flow capability. The lower the number,
the better the flow. The second viscosity grade num-
ber (without a W suffix) is the warm/hot-temperature
viscosity. The viscosity increases with engine temper-
ature. With a single viscosity grade, the oil viscosity
is valid only for one narrow temperature range.
Fig. 1 Unleaded Fuel Only RemindersÐFuel Gauge
Fig. 2 Unleaded Fuel Only ReminderÐFuel Filler
Door
Fig. 3 SAE Oil Viscosity Grade & API Service Grade
0 - 2 LUBRICATION AND MAINTENANCEJ

MAINTENANCE SCHEDULES
INTRODUCTION
Chrysler Corporation has compiled recommended
lubrication and maintenance schedules and proce-
dures to help reduce premature wear or failure over
a broad range of operating conditions.
SEVERE SERVICE MAINTENANCE
If the vehicle is involved with a severe driving con-
dition, after each 4 800-km (3,000-miles)/3-month in-
terval. A severe driving condition includes:
²frequent short trip driving less than 24 km (15
miles);
²frequent driving in a dusty environment;
²trailer towing;
²extensive engine idling;
²sustained high-speed operation;
²desert operation;
²frequent starting and stopping;
²cold-climate operation;
²off-road driving; or
²commercial service.
MAINTENANCE SCHEDULES
AT EACH STOP FOR FUEL
²Check engine oil level, add as required.
²
Check windshield washer solvent and add if required.
ONCE A MONTH
²Check tire pressure and look for unusual wear or
damage.
²Inspect battery and clean and tighten terminals as
required.
²Check electrolyte level and add water as needed.
²Check fluid levels of coolant reservoir, power steer-
ing and transmission and add as needed.
²Check all lights and all other electrical items for
correct operation.
²Check rubber seals on each side of the radiator for
proper fit.
7,500 MILES (12 000 KM) OR AT 6 MONTHS
²Check engine coolant level, hoses and clamps.
²Change engine oil.
²Replace engine oil filter.
²Check exhaust system.
²Lubricate steering linkage (4x4 models).
²Lubricate propeller shaft universal joints.
²Rotate Tires.
15,000 MILES (24 000 KM) OR AT 12 MONTHS
²Check engine coolant level, hoses and clamps.
²Change engine oil.
²Replace engine oil filter.
²Check exhaust system.
²Lubricate steering linkage (4x4 models).
²Lubricate propeller shaft universal joints.²Check fluid level in battery.
²Rotate Tires.
22,500 MILES (36 000 KM) OR AT 18 MONTHS
²Check engine coolant level, hoses and clamps.
²Change engine oil.
²Replace engine oil filter.
²Check exhaust system.
²Lubricate steering linkage (4x4 models).
²Lubricate propeller shaft universal joints.
²Rotate Tires.
30,000 MILES (48 000 KM) OR AT 24 MONTHS
²Replace air cleaner filter.
²Replace spark plugs.
²Adjust drive belt.
²Check engine coolant level, hoses and clamps.
²Change engine oil.
²Replace engine oil filter.
²Check exhaust system.
²Lubricate steering linkage (4x4 models).
²Lubricate propeller shaft universal joints.
²Check fluid level in battery.
²Drain and refill automatic transmission.
²Drain and refill transfer case.
²Rotate Tires.
37,500 MILES (60 000 KM) OR AT 30 MONTHS
²Check engine coolant level, hoses and clamps.
²Change engine oil.
²Replace engine oil filter.
²Check exhaust system.
²Lubricate steering linkage (4x4 models).
²Lubricate propeller shaft universal joints.
²Drain and refill manual transmission.
²Rotate Tires.
45,000 MILES (72 500 KM) OR AT 36 MONTHS
²Check engine coolant level, hoses and clamps.
²Change engine oil.
²Replace engine oil filter.
²Check exhaust system.
²Lubricate steering linkage (4x4 models).
²Lubricate propeller shaft universal joints.
²Check fluid level in battery.
²Rotate Tires.
52,500 MILES (84 500 KM) OR AT 42 MONTHS
²Flush and replace engine coolant.
²Check engine coolant system hoses and clamps.
²Change engine oil.
²Replace engine oil filter.
²Check exhaust system.
²Lubricate steering linkage (4x4 models).
²Lubricate propeller shaft universal joints.
²Rotate Tires.
JLUBRICATION AND MAINTENANCE 0 - 5

JUMP STARTING, HOISTING AND TOWING
JUMP STARTING
WARNING: DO NOT ATTEMPT TO PUSH OR TOW A
VEHICLE TO START THE ENGINE. UNBURNED
FUEL COULD ENTER THE EXHAUST CATALYTIC
CONVERTER AND IGNITE AFTER THE ENGINE IS
STARTED. THIS COULD CAUSE THE CONVERTER
TO OVERHEAT AND RUPTURE.
BOOSTER BATTERY
WARNING: TO PREVENT PERSONAL INJURY OR
CLOTHING DAMAGE, DO NOT ALLOW BATTERY
(ACID) TO CONTACT EYES, SKIN OR CLOTHING.
DO NOT LEAN OVER A BATTERY WHEN CON-
NECTING JUMPER CABLES. DO NOT ALLOW THE
POSITIVE AND NEGATIVE CABLE CONNECTOR
CLAMPS TO CONTACT EACH OTHER. KEEP OPEN
FLAMES AND SPARKS AWAY FROM THE BATTERY
VENT HOLES. ALWAYS WEAR EYE PROTECTION
WHEN INVOLVED WITH BATTERIES.
If it is necessary to use a booster battery and
jumper cables to start an engine use the following
procedure.
(1) Engage the parking brake and shift the auto-
matic transmission to PARK, manual transmission
shift to NEUTRAL.
(2) Turn off all lights, the heater-A/C blower mo-
tor, and all other electrical loads.
WARNING: WHEN THE AIR TEMPERATURE IS BE-
LOW THE FREEZING POINT (0ÉC OR 32ÉF), THE
ACID IN A DISCHARGED VEHICLE BATTERY CAN
FREEZE. DO NOT ATTEMPT TO JUMP START AN
ENGINE BEFORE DETERMINING THE CONDITION
OF THE BATTERY.
(3) Inspect the general condition of the battery.
CAUTION: Do not permit metal surfaces on vehicles
to contact because this could establish ground con-
tinuity between vehicle bodies.
(4) Attach a red cable connector clamp to the pos-
itive (+) terminal on the booster battery. Connect
the other red cable connector clamp to the positive
(+) terminal on the discharged battery (Fig. 6).
CAUTION: Use care to avoid allowing the positive
(+) and negative (-) cable clamps to contact each
other. DO NOT lean over the battery when connect-
ing the cable clamps.WARNING: DO NOT CONNECT A JUMPER CABLE
CONNECTOR CLAMP TO THE NEGATIVE POST OF
THE DISCHARGED BATTERY.
(5) Connect a black jumper cable connector clamp
to the negative (-) terminal on the booster battery.
Connect the other black jumper cable connector
clamp to a good ground.
(6) Start the engine.
WARNING: THE USE OF ANY JUMPER CABLE DIS-
CONNECTION PROCEDURE OTHER THAN THAT
DESCRIBED BELOW COULD RESULT IN:
²PERSONAL INJURY CAUSED BY BATTERY
ELECTROLYTE SQUIRTING FROM THE BATTERY
VENTS.
²PERSONAL INJURY AND/OR PROPERTY DAM-
AGE CAUSED BY BATTERY EXPLOSION.
²DAMAGE TO THE BOOSTER VEHICLE OR THE
DISABLED VEHICLE CHARGING SYSTEM.
(7) After the engine is started, or if the engine
fails to start, the jumper cables must be disconnected
in the following order:
²Black (negative) cable connector clamp from the
engine ground contact.
²Black (negative) cable connector clamp from the
negative terminal (-) on the booster battery.
²Red (positive) cable connector clamps from the pos-
itive (+) terminals on both batteries.
Fig. 6 Jumper Cable Connections
JLUBRICATION AND MAINTENANCE 0 - 7

ENGINE OIL CHANGE AND FILTER REPLACEMENT
WARNING: CARE SHOULD BE TAKEN WHEN
CHANGING OIL. PROTECTIVE CLOTHING AND
GLOVES SHOULD BE WORN. EXPOSED SKIN
SHOULD BE WASHED WITH SOAP AND WATER TO
REMOVE ANY ENGINE OIL. DO NOT USE GASO-
LINE, THINNER, OR SOLVENTS TO REMOVE EN-
GINE OIL FROM SKIN.
REQUIRED MAINTENANCE
With normal driving conditions, engine oil and fil-
ter must be changed after each 12 000-km (7,500-
miles)/12-month interval. If the vehicle is involved
with a severe driving condition, after each 4 800-km
(3,000-miles)/3-month interval. A severe driving con-
dition includes:
²frequent short trip driving less than 24 km (15
miles);
²frequent driving in a dusty environment;
²trailer towing;
²extensive engine idling;
²sustained high-speed operation;
²desert operation;
²frequent starting and stopping;
²cold-climate operation;
²off-road driving; or
²commercial service.
OIL CHANGE AND FILTER REPLACEMENT
(1) Drain the engine oil from the crankcase. Wait
until after the engine has attained the normal oper-
ating temperature to ensure complete drainage of oil.
(2) Install the drain-hole plug with a replacement
gasket.
The oil filter should be replaced during every
engine oil change.
(3)
Rotate the oil filter counterclockwise to remove
it from the cylinder block oil filter boss (Figs. 6 and 7).
(4) Clean the cylinder block oil filter boss.
(5) Apply a light coat of engine oil to the rubber
seal on the replacement oil filter.
CAUTION: Do not use oil filter with metric threads.
The proper oil filter has SAE type 3/4 X 16 threads.
The use of an oil filter with metric threads can re-
sult in engine oil leaks and engine failure.
(6) Install andhand tightenthe oil filter 1/2 to
3/4 of-a-turn clockwise beyond the point where the
seal first contacts the cylinder block.
(7) Add engine oil in fill hole located on top of en-
gine cylinder head cover (Fig. 8).
(8) Observe the oil level on the dipstick. Add oil,
if necessary, to increase the level to the FULL mark.
Fig. 6 Oil Filter RemovalÐ2.5L Engine
Fig. 7 Oil FilterÐ4.0L Engine
Fig. 8 Adding Engine OilÐTypical
JLUBRICATION AND MAINTENANCE 0 - 15

CAUTION: Do not tap the filter element or immerse
the filter in liquid to remove trapped particles.
(3) Clean filter element by gently blowing the
trapped particles from the filter with compressed air.
Direct air in the opposite direction of normal intake
air flow. Keep air nozzle at least two inches away
from the filter to avoid damage to filter.
(4) If the filter has become partially saturated with
oil, replace the filter. Test the crankcase ventilating
(CCV) system for proper operation.
(5) Wash the air cleaner cover and body/housing
(Figs. 10) with cleaning solvent and wipe dry.
(6) Install the air cleaner filter element and attach
the cover to the body/housing.
CRANKCASE VENTILATION SYSTEM
All Jeept2.5L and 4.0L engines are equipped with
a crankcase ventilation (CCV) system. Refer to
Group 25ÐEmissions, for additional information.
FUEL USAGE STATEMENTÐGAS ENGINES
Jeeptvehicles are designed to meet all emission
regulations and provide excellent fuel economy using
high quality unleaded gasoline. Only use unleaded
gasolines having a minimum posted octane of 87.
If a Jeeptvehicle develops occasional light spark
knock (ping) at low engine speeds, this is not harm-
ful. However,continued heavy knock at high
speeds can cause damage and should be
checked immediately.Engine damage as a result of
heavy knock operation may not be covered by the
new vehicle warranty.In addition to using unleaded gasoline with the
proper octane rating,those that contain deter-
gents, corrosion and stability additives are rec-
ommended.Using gasolines that have these
additives will help improve fuel economy, reduce
emissions and maintain vehicle performance. Gener-
ally, premium unleaded gasolines contain more addi-
tive than regular unleaded gasolines.
Poor quality gasolinecan cause problems such as
hard starting, stalling and stumble. If these problems
occur, use another brand of gasoline before consider-
ing servicing the vehicle.
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with
materials that contain oxygen such as alcohol, MTBE
and ETBE. The type and amount of oxygenate used
in the blend is important. The following are gener-
ally used in gasoline blends:
ETHANOL
Ethanol (Ethyl or Grain Alcohol) properly blended,
is used as a mixture of 10 percent ethanol and 90
percent gasoline.Gasoline with ethanol may be
used in your vehicle.
METHANOL
CAUTION: Do not use gasolines containing metha-
nol. Use of methanol/gasoline blends may result in
starting and driveability problems. In addition, dam-
age may be done to critical fuel system compo-
nents.
Methanol (Methyl or Wood Alcohol) is used in a va-
riety of concentrations blended with unleaded gaso-
line. You may encounter fuels containing 3 percent
or more methanol along with other alcohols called co-
solvents.
Problems that are the result of using methanol/gas-
oline blends are not the responsibility of Chrysler
Corporation. They may not be covered by the vehicle
warranty.
MTBE/ETBE
Gasoline and MTBE (Methyl Tertiary Butyl Ether)
blends are a mixture of unleaded gasoline and up to
15 percent MTBE. Gasoline and ETBE (Ethyl Ter-
tiary Butyl Ether) are blends of gasoline and up to
17 percent ETBE. Gasoline blended with MTBE or
ETBE may be used.
CLEAN AIR GASOLINE
Many gasolines are now being blended that con-
tribute to cleaner air, especially in those areas of the
country where air pollution levels are high. These
new blends provide a cleaner burning fuel and some
are referred to asReformulated Gasoline.
Fig. 10 Air Cleaner Body/Housing & Cover
JLUBRICATION AND MAINTENANCE 0 - 17

ENGINE SUPPORTS
RECOMMENDED MAINTENANCE
The general condition of the engine supports
should be inspected at the same time as the engine
oil is changed and the oil filter is replaced.
INSPECTION
(1) Test the hardware that attaches the engine cyl-
inder block to the engine support brackets (Figs. 17
and 18) for the specified tightening torque.
(2) Inspect the rubber in the engine support cush-
ions for softening and swelling. Slight surface deteri-
oration and wear at the ends will not affect the
functioning of an engine support.
ACCESSORY DRIVE BELT
RECOMMENDED MAINTENANCE
The accessory drive belt should be inspected for
cracks, fraying, and excessive wear. If necessary, re-
fer to Group 7ÐCooling Systems for replacement pro-
cedures and adjustment specifications.
REQUIRED MAINTENANCE
The drive belt must be adjusted after each 48
000-km (30,000-miles) interval of vehicle operation
has elapsed. The accessory drive belt must be re-
placed after each 96 000-km (60,000-miles). If neces-
sary, refer to Group 7ÐCooling Systems.
EXHAUST SYSTEM
REQUIRED MAINTENANCE
The general condition of the exhaust system must
be inspected after each 12 000-km (7,500-miles).
An exhaust system must be properly aligned to
prevent stress, leakage, and vehicle body contact.
Fig. 17 Front Engine SupportÐTypical
Fig. 18 Rear Engine SupportÐTypical
Fig. 15 ATF Cooler Hoses ÐXJ Vehicles
Fig. 16 ATF Cooler Hoses (4.0L)ÐYJ Vehicles
0 - 20 LUBRICATION AND MAINTENANCEJ

Under normal driving conditions, manual trans-
mission lube oil should be changed after each 60
000-km (37,500 miles). With severe driving condi-
tions, after each 29 000-km (18,000 miles).
LUBRICANT SPECIFICATION
When it becomes necessary to add to or change the
lube oil in a Jeeptmanual transmission, use SAE
75W-90, API Quality Grade GL-5 gear lubricant.
LUBRICANT LEVEL
The fill-hole plug for all manual transmissions is
located on the right side of the case (Fig. 4). Deter-
mine the lubricant level according to the following
procedure.
(1) Remove the fill-hole plug (Fig. 4) from the
transmission. The lube oil should be level with the
bottom edge of the fill hole. The level can be slightly
below the bottom edge of the fill hole if the lube oil
is cold.
If the transmission is warm, lube oil could drip
out of the fill hole. This is acceptable but the
lube oil should not gush out of the fill hole.
(2) If not acceptable, raise the lube oil level to the
bottom edge of the transmission fill hole. Use SAE
75W-90, API Quality Grade GL-5 gear lubricant.
Add lube oil in small amounts to raise the
level.
(3) Install the fill-hole plug in the transmission.
Tighten the plug with 37 NIm (27 ft. lbs.) torque.
LUBE OIL CHANGE
When it becomes necessary to change manual
transmission lube oil, use the following procedure.
(1) Raise and support the vehicle.
(2) Remove the fill-hole plug from the transmis-
sion.
(3) Place a container to collect the lube oil under
the transmission drain-hole plug.(4) Remove the drain-hole plug and drain the lube
oil from the transmission into the container.
Care should be exercised when disposing used
lube oil after it has been drained from a trans-
mission.
(5) Install the drain-hole plug in the transmission.
Tighten the plug with 37 NIm (27 ft. lbs.) torque.
(6) Fill the transmission until the lube oil begins
to drip out of the fill hole with SAE 75W-90, API
Quality Grade GL-5 gear lubricant.
(7) Install the fill-hole plug in the transmission.
Tighten the plug with 37 NIm (27 ft. lbs.) torque.
(8) Remove the support and lower the vehicle.
AUTOMATIC TRANSMISSION
RECOMMENDED MAINTENANCE
Check fluid level in automatic transmissions (Fig.
5) the same time the engine oil is changed and the
oil filter is replaced. Add ATF as necessary.
Under normal driving conditions, the ATF should
be changed and the filter replaced after each 48
000-km (30,000-miles). With severe driving condi-
tions, after each 29 000-km (12,000-miles).
ATF SPECIFICATIONS
When it becomes necessary to add fluid (ATF) to a
Jeeptautomatic transmission (or when the ATF is
replaced), use:
²MerconŸ ATFonlyfor AW-4 automatic transmis-
sions (XJ vehicles), and
²MOPAR ATF PLUS type 7176 (or an equivalent
MerconŸ/Dexron IIŸ ATF) for 998 automatic trans-
missions (YJ vehicles).
SPECIAL ADDITIVES
The addition of any special-type fluid to a Jeept
automatic transmission is not recommended. The
only exception is the addition of black-light detection
Fig. 5 AW-4 Automatic Transmission (XJ)
Fig. 4 Manual Transmission Fill- & Drain-Hole
PlugsÐTypical
JLUBRICATION AND MAINTENANCE 0 - 23

dye to aid in detecting the source of ATF leaks. The
use of transmission sealing additives should also be
avoided.
Black-light detection dye is factory-installed in
automatic transmissions and, unless the ATF
has been drained and re-placed, it is not neces-
sary to add dye.
ATF LEVEL
Determine the ATF level according to the following
procedure.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT PUT YOUR
HANDS NEAR THE DRIVE BELT, PULLEYS OR FAN
BLADE. DO NOT STAND IN A DIRECT LINE WITH
THE FAN BLADE.
(1) Operate the engine and allow the automatic
transmission sufficient time to warm to the normal
operating temperature (77ÉC/170ÉF).
When at normal operating temperature, ATF
will be uncomfortable to fingertips when the
dipstick is touched. Normally, 25 km (15 miles) is
a sufficient driving distance for a transmission
to warm to normal operating temperature (77ÉC/
170ÉF).
(2) Place the vehicle on a level surface.
(3) Operate the engine at idle speed.
(4) Engage the parking brake.
(5) Place a block in front of and at the rear of one
wheel/tire to prevent vehicle movement.
(6) Depress the brake pedal and move the trans-
mission selector lever through all the positions and
then place the selector lever in NEUTRAL position.
(7) Remove the dipstick (Fig. 6) from the transmis-
sion filler tube and wipe it clean.
(8) Insert the dipstick into the transmission filler
tube and seat the cap on top of the tube.
(9) Remove the dipstick and observe the ATF level
on both sides of the dipstick. The ATF level is accept-
able when it is between the ADD and FULL marks.
(10) While determining the ATF level in a trans-
mission, also note the general condition of the fluid.
Examine the fluid closely. If doubtful about its con-
dition, drain a sample into a small container for
evaluation.
(11) If the ATF level is either at or below the ADD
mark, add sufficient ATF to raise the level to the
FULL mark on the dipstick.
CAUTION: Do not over-fill an automatic transmis-
sion. Over-filling can cause the ATF to foam, which
will result in over-heating, fluid oxidation and var-
nish formation.
(12) When it is necessary to add ATF, insert a
long-necked funnel into the transmission filler tube.It requires only 0.5 liter (1.0 pint) of ATF to raise
the level from the ADD mark to the FULL mark.
(13) Inspect for ATF leaks and correct as neces-
sary.
(14) Remove the wheel/tire blocks.
ATF AND FILTER CHANGE
Automatic transmission fluid (ATF) does not dete-
riorate or wear out, but it does become contaminated.
These contaminates will eventually restrict passages
and orifices. The result is hard or rough shifting, or
complete transmission failure. Also, the varnish
eventually causes rubber seals to harden and become
brittle.
When it is necessary to change the ATF and re-
place the filter in a Jeeptautomatic transmission,
use the following procedures.
Fig. 6 Dipstick & ATF LevelÐTypical
Fig. 7 Safe ATF Level Above 22ÉC/72ÉF
0 - 24 LUBRICATION AND MAINTENANCEJ

DRAINING ATF/FILTER REMOVAL
Drain the automatic transmission fluid (ATF) im-
mediately after stopping the engine (before the ATF
cools).
(1) Raise and support the vehicle.
(2) Loosen the transmission pan bolts and drain
the original ATF into an appropriate container. Re-
move the pan bolts, the pan and the gasket.
Care should be exercised when disposing used
ATF after it has been drained from a vehicle
transmission.
(3) Remove the screws and the ATF filter (Fig. 8).
Discard the filter.
FILTER INSTALLATION/ATF RE-FILL
(1) Install a replacement ATF filter. Tighten the
screws with 4 NIm (35 in. lbs.) torque.
(2) Clean the pan thoroughly. Install a replace-
ment gasket on the pan. Install the pan with the at-
taching bolts:
²model AW-4 transmission Ð tighten the pan bolts
with 7 NIm (60 in. lbs.) torque; and
²model 998 transmission Ð tighten the pan bolts
with 17 NIm (150 in. lbs.) torque.
(3) Remove the support and lower the vehicle.
(4) Pour approximately 4.7 liters (5 quarts) of ATF
into the filler tube. Use MerconŸ ATF for AW-4 au-
tomatic transmissions. Use MOPAR ATF PLUS type
7176 or equivalent, for 998 automatic transmissions.
(5) Place a block in front of and at the rear of one
wheel/tire to prevent vehicle movement.
(6) Start the engine and allow it to idle a few min-
utes.
(7) Apply the brake pedal and engage the parking
brake. Move the transmission selector lever through
all positions, then place the selector lever in NEU-
TRAL position.(8) With the transmission at normal operating
temperature, observe the ATF level on the dipstick.
Add ATF (if necessary) to raise the level to the
FULL mark on the dipstick.Only 0.5 liter (1.0 pint)
will raise the level from the ADD mark to the
FULL mark when the ATF is at normal operat-
ing temperature.
(9) Inspect for fluid leaks and correct as necessary.
(10) Remove the wheel/tire blocks.
TRANSFER CASE
RECOMMENDED MAINTENANCE
The fluid (ATF) level in transfer cases should be
determined at the same time as the engine oil is
changed and the oil filter is replaced. Add ATF as
necessary.
In addition, transfer case ATF should be changed
after each 48 000-km (30,000-miles) interval of vehi-
cle operation has elapsed.
FLUID SPECIFICATIONS
If it is necessary to add fluid to a transfer case (or
when the fluid is changed), use MOPAR ATF PLUS
type 7176 or an equivalent MerconŸ/Dexron IIŸ
ATF.
FLUID LEVEL
The transfer case fill-hole plug is located at the
rear of the housing (Fig. 9).
Determine the transfer case fluid (ATF) level ac-
cording to the following procedure.
(1) Raise and support the vehicle.
(2) Remove the fill-hole plug from the transfer
case. The ATF level should be at the bottom edge of
the fill hole. The level can be slightly below the bot-
tom edge of the fill hole if the fluid is cold.
Fig. 9 Transfer CaseÐTypical
Fig. 8 ATF FilterÐTypical
JLUBRICATION AND MAINTENANCE 0 - 25

FRONT WHEEL BEARINGS
Only 2WD XJ vehicles are equipped with front
wheel bearings. XJ vehicles have semi-floating axle
shafts and axle shaft bearings that are lubricated via
differential lube oil.
RECOMMENDED MAINTENANCEÐ2WD XJ
VEHICLES
The front wheel bearings should be lubricated (re-
packed) at the same time as front brake pad/caliper
service is conducted.
LUBRICANT SPECIFICATION
Wheel bearings should be lubricated with a lubri-
cant that is identified as NLGI GC-LB lubricant.
INSPECTION/LUBRICATION
(1) Remove the wheel/tire and the disc brake cali-
per.Do not disconnect the caliper brake fluid
hose unless the caliper must also be removed for
maintenance. Support the caliper with a hanger
to prevent brake fluid hose damage.
(2) Remove the dust cap, the cotter pin, the nut re-
tainer, the adjustment nut, and the thrust washer
from the spindle (Fig. 3). Discard the cotter pin.
(3) Remove the wheel outer bearing from the hub.
(4) Remove the wheel hub/disc brake rotor from
the spindle.
(5) Remove the seal and the inner wheel bearing
from the hub cavity.
(6) After removal, inspect both front wheel bearing
races for indications of pitting, brinelling and exces-
sive heat.
(7) Wipe the spindle clean and apply a small
amount of chassis/wheel bearing lubricant (NLGI
GC-LB lubricant) to prevent rust. Wipe the wheel
hub cavity clean.
CAUTION: Do not over-fill the wheel hub cavity with
lubricant. Excessive lubricant can cause overheat-ing and bearing damage. Also, excessive lubricant
can be forced out of the wheel hub cavity and con-
taminate the brake rotor/pads.
(8) Partially fill the wheel hub cavity with chassis/
wheel bearing lubricant (NLGI GC-LB lubricant).
(9) Pack the wheel bearings with chassis/wheel
bearing lubricant (NLGI GC-LB lubricant). Ensure
that sufficient lubricant is forced between the bear-
ing rollers.
(10) Install the wheel inner bearing in the wheel
hub and install a replacement seal.
(11) Clean the disc brake rotor contact surfaces, if
necessary.
(12) Install the wheel hub/disc brake rotor on the
spindle.
(13) Install the wheel outer bearing, the thrust
washer, and the spindle nut.
(14) Tighten the spindle nut with 28 NIm (21 ft.
lbs.) torque while rotating the disc brake rotor to
seat the bearings.
(15) Loosen the spindle nut 1/2 turn. While rotat-
ing the disc brake rotor, tighten the spindle nut with
2NIm (19 in. lbs.) torque.
(16) Install the nut retainer and a replacement cot-
ter pin.
(17) Clean the dust cap and apply wheel bearing
lubricant to the inside surface.Do not fill the dust
cap with lubricant.
(18) Install the dust cap.
(19) Install the disc brake caliper.
POWER STEERING SYSTEM
RECOMMENDED MAINTENANCE
The condition of power steering system should be
inspected and the fluid level checked. Add fluid as
necessary.
FLUID SPECIFICATION
Jeeptpower steering systems require MOPAR
Power Steering Fluid, or an equivalent product.
The original power steering fluid installed in
Jeeptvehicles includes black-light leak detec-
tion dye.
INSPECTION
Inspect the power steering system (Figs. 4 and 5)
for the sources of fluid leaks, steering gear housing
cracks and ensure that the steering gear is securely
attached to the vehicle frame rail. Inspect the steer-
ing damper for leaks and loose connections.
FLUID LEVEL
The fluid level dipstick is attached to the reservoir
cap (Fig. 6). The fluid level in the reservoir can be
determined with the fluid either hot or cold.
(1) Remove the cap from the reservoir.
Fig. 3 2WD Front Wheel BearingsÐXJ Vehicles
JLUBRICATION AND MAINTENANCE 0 - 31