service JEEP CHEROKEE 1994 Service Repair Manual

LUBRICATION AND MAINTENANCE
CONTENTS
page page
CHASSIS AND BODY COMPONENTS....... 30
DRIVETRAIN........................... 22
ENGINE MAINTENANCE.................. 13GENERAL INFORMATION.................. 1
JUMP STARTING, HOISTING AND TOWING . . 7
MAINTENANCE SCHEDULES............... 5
GENERAL INFORMATION
INDEX
page page
Classification of Lubricants.................. 2
Components Requiring No Lubrication.......... 3
Fluid Capacities.......................... 4
Fuel Requirements........................ 2Introduction.............................. 1
Recommended Lubricant and Replacement Parts . 3
Routine Service........................... 2
INTRODUCTION
Jeeptlubrication and maintenance is divided into
required and recommended service tasks.
The recommendations and procedures listed in this
group are intended for JeeptDealer Service Personnel.
Because conditions vary, it is necessary to schedule
service tasks according to a time interval as well as a
distance interval.
It is the owner's responsibility to have vehicle ser-
viced. Owner is to pay for labor and necessary parts
that are not covered by the warranty.
Additional lubrication and maintenance informa-
tion is listed in the Owner's Manual, which is in-
cluded with the vehicle.
SEVERE DRIVING CONDITIONS
When a vehicle is subjected to a severe driving con-
dition, time between recommended maintenance
should be decreased.
Refer to Engine Maintenance for the engine oil and
filter maintenance interval when involved with a se-
vere driving condition.
A severe driving condition is defined as either:
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.
To service a Jeeptvehicle for a severe driving con-
dition, change all the lubricating fluids and lubricate:
²the body components,
²all the driveline coupling joints, and
²the steering linkage
more often than for a normal driving condition to
prevent excessive wear of the components.
DUSTY AREAS
Driving in an area with dust-filled air increases the
risk of particles entering the engine and crankcase.
With this type of severe driving condition, attention
should be given to the engine and crankcase compo-
nents.
OFF-ROAD (4WD) OPERATION
After completion of off-road (4WD) operation, the
underside of the vehicle should be thoroughly in-
spected. Examine threaded fasteners for looseness.
HARSH SURFACE ENVIRONMENTS
After vehicle operation in a harsh surface environ-
ment, the following components should be inspected
and cleaned as soon as possible:
²brake drums,
²brake linings,
²front wheel bearings (2WD vehicles only), and
²axle coupling joints.
This will prevent wear and/or unpredictable brake
action.
JLUBRICATION AND MAINTENANCE 0 - 1

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

Above that temperature range the viscosity will de-
crease, and below that range the viscosity will in-
crease.
An engine oil with an SAE 5W-30 viscosity grade
provides good flow capability for fast cold weather
engine starts. The viscosity will then increase with
engine temperature to provide good high-tempera-
ture engine lubrication.
API SERVICE GRADE
The API Service Grade specifies the type of engine/
operating conditions for which the oil is intended.
The API Service Grade specifications also apply to
energy conserving engine oils (Fig. 3). The API cer-
tification mark is also used indicating that the oil is
certified to meet the most critical requirements es-
tablished by the manufacturer (Fig. 4).
For maximum protection, use API Service Grade
SG, SG/CD or SG/CE engine oil in Jeeptengines.
GEAR LUBRICANTS
A dual SAE viscosity grade is also used to specify
the viscosity of multipurpose gear lubricants.
The API lubrication quality grade designation
identifies gear lubricants in terms of recommended
usage.
CHASSIS COMPONENT AND WHEEL BEARING
LUBRICANTS
The chassis component and wheel bearing lubri-
cants are identified by the NLGI Certification Sym-
bol (Fig. 5).
The letterGindicates wheel bearing lubricant and
the letterLindicates chassis lubricant. When the
letters are combined the lubricant can be used for
dual applications. The suffix lettersCandBindi-
cates quality level of the lubricant. Use only lubri-
cants that display the NLGI Certification Symbol.
RECOMMENDED LUBRICANT AND REPLACEMENT
PARTS
Jeeptvehicles are engineered to provide many
years of dependable operation. When necessary,MO-
PAR brand lubricants and genuine replacement
partsare highly recommended.
COMPONENTS REQUIRING NO LUBRICATION
There are many components that should not be lu-
bricated. The components that shouldnotbe lubri-
cated are:
²air pumps;
²generator bearings;
²drive belts;
²drive belt idler pulleys;
²rubber bushings;
²starter motor bearings;
²suspension strut bearings;
²throttle control cables;
²throttle linkage ball joints; and
²water pump bearings.
Fig. 4 The API Engine Oil Certification Mark
Fig. 5 NLGI Lubricant Certification/Identification
Symbol
JLUBRICATION AND MAINTENANCE 0 - 3

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

ENGINE MAINTENANCE
INDEX
page page
Accessory Drive Belt...................... 20
Air-Conditioner Compressor/Hoses/Fittings...... 21
Battery................................ 18
Cooling System.......................... 16
Crankcase Ventilation System............... 17
Engine Air Cleaner Filter Element............ 16
Engine Break-In......................... 13
Engine Oil.............................. 13Engine Oil Change and Filter Replacement..... 15
Engine Oil Filter......................... 14
Engine Supports......................... 20
Exhaust System......................... 20
Fuel Usage StatementÐGas Engines......... 17
Ignition Cables, Distributor Cap and Rotor...... 18
Rubber and Plastic Ducts/Hoses/Tubing....... 19
Spark Plugs............................ 18
ENGINE BREAK-IN
After first starting a new engine, allow it to idle
and warm up for at least 15 seconds before shifting
the transmission into a drive gear.
Drive the vehicle at:
²varying speeds less than 80 km/h (50 mph) for the
first 160 km (100 miles), and
²speeds less than 88 km/h (55 mph) for the first 800
km (500 miles).
Avoid driving at full-throttle for extended periods
of time. Also, avoid fast acceleration and sudden
stops.
A special break-in engine oil is not required. The
original oil installed in a vehicle is a quality lubri-
cant. There is no requirement to have the oil
changed or the oil filter replaced until the first
scheduled maintenance interval.
The engine oil, coolant and all the other engine re-
lated fluid levels should be determined on a regular
basis.
ENGINE OIL
SPECIFICATIONS
API SERVICE GRADE
For maximum engine protection during all driving
conditions, install an engine oil that conforms to API
Service Grade. MOPAR Engine Oil conforms to all of
these API Service Grades.
SAE VISCOSITY
SAE designated multi-viscosity grade engine oil is
to protect engines. This type of engine oil can usually
be installed and remain in the engine until the next
scheduled oil change. Select the engine oil viscosity
according to the lowest ambient air temperature ex-
pected before the next scheduled oil change (Fig.1).
Low viscosity engine oil allows easier engine starting
during cold weather. SAE 5W-30 viscosity engine oil
is recommended when the ambient air temperatures
consistently decrease to below 10ÉF (-12ÉC).ENERGY CONSERVING OIL
In selecting the correct API grade and SAE grade,
anENERGY CONSERVINGtype engine oil is also
recommended.
CONTAINER IDENTIFICATION
Standard engine oil notations have been adopted
for selection of engine oil. The notations are located
on side of plastic bottles and on the top of engine oil
cans (Fig. 2).
²The top, outer field contains theAPI Service
Gradenotation for the engine oil.
Fig. 1 Temperature/Engine Oil Viscosity
Fig. 2 Engine Oil Container Standard Notations
JLUBRICATION AND MAINTENANCE 0 - 13

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 overfill the engine crankcase with
oil. This will cause oil aeration and result in a de-
crease in the engine oil pressure.
(9) Start the engine and observe the oil pressure
gauge or warning lamp. If the pressure does not in-
crease or the warning lamp does not go out, stop the
engine and determine the cause of the problem.
USED ENGINE OIL DISPOSAL
Care should be exercised when disposing used en-
gine oil after it has been drained from a vehicle en-
gine. Refer to the WARNING listed above.
COOLING SYSTEM
WARNING: USE EXTREME CAUTION WHEN RE-
MOVING THE RADIATOR CAP IF THE ENGINE IS
OPERATING. DO NOT PUT YOUR HANDS NEAR
THE DRIVE BELT(S), PULLEYS OR FAN BLADE. DO
NOT STAND IN A DIRECT LINE WITH THE FAN
BLADE.
RECOMMENDED MAINTENANCE
The engine coolant level should be determined at
least once a month and more often during periods of
hot weather. Add coolant as necessary.
COOLANT LEVEL
With the engine at normal operating temperature,
observe the coolant level in thecoolant recovery bot-
tle. The coolant level must be at least above the ADD
mark and preferably at the FULL mark. Add coolant
to the coolant recovery bottleonly, if necessary.
REQUIRED MAINTENANCE
Check coolant level, and inspect condition of cool-
ing system hoses and clamps after each 12 000-km
(7,500-miles).
Initially, coolant must be drained and cooling sys-
tem flushed and filled after the first 36 months of op-
eration. Thereafter, after each 24-months interval of
vehicle operation.
RECOMMENDED MAINTENANCE
The engine cooling system should be inspected for
proper operation and for component failure at least
every 12 months.
WARNING: IF THE ENGINE HAS BEEN RECENTLY
OPERATED, USE EXTREME CARE WHEN REMOV-
ING THE RADIATOR CAP TO AVOID SCALDING
WITH HOT, PRESSURIZED COOLANT.
For additional information, refer to Section 7, Cool-
ing System.COOLANT FREEZE PROTECTION
Jeeptcooling systems contain a 50/50 mixture of
anti-freeze and distilled water coolant. This is the
recommended coolant mixture for most ambient tem-
peratures. The factory-installed anti-freeze is formu-
lated to prevent corrosion on all cooling system metal
surfaces.
The degree of coolant freeze protection should be
tested every 12 months. If the coolant is contami-
nated orrustyin appearance, cooling system should
be drained and filled with a 50/50 mixture of fresh
coolant. For additional information, refer to Group
7ÐCooling System.
ENGINE AIR CLEANER FILTER ELEMENT
RECOMMENDED MAINTENANCE
Engine performance and fuel economy can be af-
fected by a restricted air cleaner filter. The filter
should be inspected on a regular basis for excessive
air restriction.
If the filter element is saturated with oil, replace
the filter element.
REQUIRED MAINTENANCE
Engine air cleaner filter must be replaced after
each 48 000-km (30,000-miles).
If a vehicle is frequently operated in dusty
areas, the air cleaner filter should be inspected
often.
FILTER ELEMENT SERVICE/REPLACEMENT
(1) Remove the air cleaner cover from the body/
housing (Fig. 9).
(2) Remove the air cleaner filter element from the
body/housing.
Fig. 9 Air Cleaner & Filter ElementÐ2.5L and 4.0L
Engines
0 - 16 LUBRICATION AND MAINTENANCEJ

In areas of the country where carbon monoxide lev-
els are high, gasolines are being treated with oxy-
genated materials such as MTBE, ETBE and
ethanol.
Chrysler Corporation supports these efforts toward
cleaner air and recommends the use of these gaso-
lines as they become available.
IGNITION CABLES, DISTRIBUTOR CAP AND
ROTOR
REQUIRED IGNITION SYSTEM MAINTENANCE
The ignition cables, distributor cap and rotor must
be replaced after each 96 000-km (60,000-miles). Re-
fer to Group 8DÐIgnition Systems for additional in-
formation.
IGNITION TIMING
The ignition timing for 2.5L and 4.0L engines is
not adjustable. Refer to the specifications listed on
the engine Emission Control Information Label. Re-
fer to Group 25ÐEmission Control Systems for addi-
tional information.
SPARK PLUGS
REQUIRED MAINTENANCE
The spark plugs must be replaced after each 48
000-km (30,000-miles). Refer to the Spark Plugs
chart below and to Group 8DÐIgnition Systems for
additional information.
BATTERY
RECOMMENDED MAINTENANCE
The battery electrolyte level should be checked and
the cable clamps should be inspected for corrosion.
This should be done when the oil is changed and the
oil filter is replaced.
The battery cables should be inspected for abnor-
mal clamp and battery terminal post corrosion. Ser-
vice the terminals and cable clamps as necessary.In addition, the general condition of the battery
should be determined before the start of cold and hot
weather seasons. If the battery condition is marginal
or worse, it should be replaced.
Care should be taken when disposing a bat-
tery after removal from a vehicle. Lead-acid bat-
teries are highly poisonous and, when
indiscriminately disposed, could create a prob-
lem for the environment. Contact the applicable
local city or county government agency to deter-
mine where automobile (lead-acid) batteries can
be properly disposed in the local area.
INSPECTION/SERVICE
WARNING: WEAR SAFETY GLASSES, RUBBER
GLOVES AND PROTECTIVE CLOTHING WHEN HAN-
DLING/SERVICING A BATTERY. THE BATTERY
ELECTROLYTE CONTAINS SULFURIC ACID AND
WILL CAUSE HARM IF IT CONTACTS SKIN, EYES
OR CLOTHING. IT WILL ALSO DAMAGE PAINTED
(AS WELL AS UN-PAINTED) SURFACES OF A VEHI-
CLE. IF SULFURIC ACID CONTACTS ANY OF
THESE, FLUSH IMMEDIATELY WITH LARGE
AMOUNTS OF WATER. IF SULFURIC ACID CON-
TACTS SKIN OR EYES, GET IMMEDIATE MEDICAL
ATTENTION. DO NOT SMOKE IN THE VICINITY OF
A BATTERY. KEEP OPEN FLAMES AND SPARKS
AWAY FROM BATTERY FILLER CAPS BECAUSE
EXPLOSIVE GAS IS ALWAYS PRESENT.
(1) Disconnect the battery negative cable and then
the positive cable.
(2) Clean the battery cable clamps and terminal
posts with a wire brush and a battery terminal
cleaner.
(3) Pry the battery cell filler caps upward to re-
move them and inspect each filler well (low-mainte-
nance batteries only, not applicable to maintenance-
free batteries). It could possibly be necessary to
loosen the battery holddown clamp to remove the
caps. Maintain the electrolyte level above the battery
plates and at the bottom of the filler well ring. Add
distilled water or low-mineral content drinking wa-
ter, if necessary. In freezing weather (below 0ÉC/
32ÉF), add the water just before driving to ensure
that it mixes thoroughly with the electrolyte. This
will prevent it from freezing.
(4) Remove the battery holddown strap and clean
the battery case/battery tray.Clean with bicarbonate
of soda (baking soda) and water. Rinse and dry the
battery case/tray thoroughly after cleaning.
(5) Position the battery in the tray and install the
holddown strap.Do not over-tighten the nuts.
(6) Connect the battery positive cable and then the
negative cable to the battery.
SPARK PLUGS
0 - 18 LUBRICATION AND MAINTENANCEJ

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

(2) Depending on fluid temperature, if the level is
below the FULL HOT mark or the FULL COLD
mark on the dipstick, add power steering fluid.
(3) Install the cap on the reservoir.
MANUAL STEERING GEARÐYJ VEHICLES
RECOMMENDED MAINTENANCE
The manual steering gear should be inspected for
damage at the same time as the engine oil is
changed and the oil filter is replaced. Repair as nec-essary (refer to Group 19ÐSteering for additional in-
formation and service procedures).
POWER BRAKE SYSTEM
RECOMMENDED MAINTENANCE
The condition of the brake system should be in-
spected and the fluid level in the master cylinder
should be checked each time the brake system is ser-
viced. Add brake fluid and repair as necessary.
In addition, the brake system should be operation-
ally tested periodically to ensure that it is function-
ing normally.
FLUID SPECIFICATION
Jeeptpower brake systems require MOPAR
Heavy-Duty Brake Fluid, or an equivalent product
identified as conforming to FMVSS No. 116, DOT-3
and SAE J-1703 specifications.
Usenew brake fluid onlywhen adding fluid to
the reservoir, to fill the brake system. Never use re-
claimed fluid.
BRAKE FLUID LEVEL
STANDARD POWER BRAKE SYSTEM
(1) Clean the cover and the sides of the brake fluid
reservoir.
(2) Detach the bail retainer from the reservoir
cover and remove the cover from the reservoir.
(3) The brake fluid level should be 6 mm (1/4 in)
below the rim of each reservoir well for XJ and YJ
Vehicles (Fig. 7). If not, add brake fluid as necessary.
(4) Inspect the reservoir cover bail retainer for ten-
sion and the cover for proper fit. The cover should fit
tight and have a good seal.
Fig. 4 Power Steering SystemÐXJ Vehicles
Fig. 5 Power Steering SystemÐYJ Vehicles
Fig. 6 Power Steering Fluid Reservoir
DipstickÐTypical
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