weight JEEP CHEROKEE 1994 Service Repair Manual

XJ FRONT SUSPENSION
INDEX
page page
Axle Bushing Replacement................. 11
Coil Spring............................. 13
Lower Suspension Arm.................... 11
Service Information....................... 10
Shock Absorber.......................... 12Spring and Shock Diagnosis................ 12
Stabilizer Bar............................ 10
Track Bar.............................. 10
Upper Suspension Arm.................... 11
SERVICE INFORMATION
CAUTION: Suspension components that use rubber
bushings should be tightened with the vehicle at
the normal height. It is important to have the
springs supporting the weight of the vehicle when
the fasteners are torqued. If the springs are not at
their normal ride position, vehicle ride comfort
could be affected along with premature bushing
wear. Rubber bushings must never be lubricated.
TRACK BAR
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the cotter pin and nut from the ball
stud end at the frame rail bracket (Fig. 1).
A puller tool may be necessary to separate the
ball stud from the frame rail bracket.
(3) Remove the bolt and flag nut from the axle
shaft tube bracket (Fig. 1). Remove the track bar.
INSTALLATION
(1) Install the track bar at axle tube bracket. Loosely
install the retaining bolt and flag nut (Fig. 1).
(2) It may be necessary to pry the axle assembly
over to install the track bar at the frame rail. Install
track bar at the frame rail bracket. Install the re-
taining nut on the stud (Fig. 1).
(3) Remove the supports and lower the vehicle.
(4) Tighten the retaining bolt at the axle shaft
tube bracket to 100 Nzm (74 ft. lbs.) torque.
(5) Tighten the ball stud nut to 81 Nzm (60 ft. lbs.)
torque. Install a new cotter pin.
STABILIZER BAR
REMOVAL
(1) Raise and support the vehicle.
(2) Disconnect the stabilizer bar links from the
axle brackets (Fig. 2).
(3) Disconnect the stabilizer bar from the links.
(4) Disconnect the stabilizer bar clamps from the
frame rails. Remove the stabilizer bar.
Fig. 2 Stabilizer BarFig. 1 Track Bar
2 - 10 FRONT SUSPENSION AND AXLEJ

COIL SPRING
REMOVAL
(1) Raise and support the vehicle. Position a hy-
draulic jack under the axle to support it.
(2) Remove the wheel if necessary.
(3) Mark and disconnect the front propeller shaft
from the axle.
(4) Disconnect the lower suspension arms from the
axle (Fig. 6).
(5) Disconnect the stabilizer bar link and shock ab-
sorber from the axle.
(6) Disconnect the track bar from the frame rail
bracket.
(7) Disconnect the drag link from the pitman arm.
(8) Lower the axle until the spring is free from the
upper mount. Remove the coil spring clip (Fig. 6) and
remove the spring.
(9) Remove the jounce bumper if necessary from
the upper spring mount (Fig. 6).
INSTALLATION
(1) Install the jounce bumper on the upper spring
mount. Tighten the bolt to 42 Nzm (31 ft. lbs.) torque
(Fig. 6).
(2) Position the coil spring on the axle pad. Install
the spring clip and bolt (Fig. 6). Tighten bolt to 21
Nzm (16 ft. lbs.) torque.
(3) Raise the axle into position until the spring
seats in the upper mount.
(4) Connect the stabilizer bar links and shock ab-
sorbers to the axle bracket. Connect the track bar to
the frame rail bracket.
(5) Install the lower suspension arms to the axle.
DO NOT TIGHTEN AT THIS TIME.
(6) Install the front propeller shaft to the axle.
(7) Remove the supports and lower the vehicle.
(8) Tighten lower suspension arms nuts to 115
Nzm (85 ft. lbs.) torque.
YJ FRONT SUSPENSION
INDEX
page page
Leaf Spring............................. 14
Leaf Spring Eye Bushing Replacement........ 15
Service Information....................... 13
Shock Absorber.......................... 14Spring and Shock Diagnosis................ 14
Stabilizer Bar............................ 14
Track Bar.............................. 13
SERVICE INFORMATION
It is important to have the springs supporting
the weight of the vehicle when the track bar fas-
teners are being torqued. If the springs are not
at their normal ride position, vehicle ride com-
fort could be affected along with premature rub-
ber bushing wear.
TRACK BAR
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the retaining nuts and bolts (Fig. 1)
from the axle bracket and frame bracket. Remove
track bar.
INSTALLATION
(1) Position track bar at axle shaft tube bracket.
Loosely install the retaining bolt and nut (Fig. 1).
(2) Loosely install the retaining bolt and nut at
the frame bracket.
(3) Remove support and lower vehicle.
(4) Tighten the retaining nut at the axle shaft
tube bracket to 100 Nzm (74 ft. lbs.) torque.
(5) Tighten the retaining nut at the frame bracket
to 142 Nzm (105 ft. lbs.) torque.
Fig. 1 Track Bar
JFRONT SUSPENSION AND AXLE 2 - 13

(2) Support the vehicle with jack stands placed un-
der the frame.
(3) Position a hydraulic jack under the axle. Raise
the axle to relieve the axle weight from the springs.
(4) Remove the stabilizer bar links attaching nut.
(5) Remove the nuts, the U-bolts and spring
bracket from the axle.
(6) Remove the nut and bolt that attaches the
spring front eye to the shackle (Fig. 3).
(7) Remove the nut and bolt from the spring rear
eye.
(8) Remove the spring from the vehicle.
The spring can be disassembled by removing
the spring clips and the center bolt. If the spring
bushings require replacement, refer to the bush-
ing removal and installation procedures.
INSTALLATION
(1) Position the spring front eye in the shackle.
Loosely install the attaching bolt and nut. Do not
tighten at this time.
(2) Position the rear eye in the hanger bracket.
Loosely install the attaching bolt and nut (Fig. 3). Do
not tighten at this time.
(3) Position the axle. Install the spring bracket,
U-bolts and nuts (Fig. 3). Tighten the U-bolt nuts to
122 Nzm (90 ft. lbs.) torque.
(4) Attach the stabilizer bar links.
(5) Remove the hydraulic jack.
(6) Remove the support stands and lower the vehi-
cle.
(7) Tighten the front shackle plate nut (Fig. 3) to
135 Nzm (100 ft. lbs.) torque.
(8) Tighten the rear eye bracket nut to 142 Nzm
(105 ft. lbs.) torque.
LEAF SPRING EYE BUSHING REPLACEMENT
(1) Assemble tools shown (Fig. 4). Tighten the nut
located at the socket wrench end of the threaded rod
until the bushing is forced out.
(2) Assemble and align the bushing installation
tools.
(3) Align the bushing with the spring eye and
tighten the nut located at the socket wrench end of
the threaded rod. Tighten until the bushing is forced
into the spring eye.
The bushing must be centered in the spring
eye. The ends of the bushing must be flush or
slightly recessed within the end surfaces of the
spring eye.
Fig. 4 Spring Eye Bushing Removal
JFRONT SUSPENSION AND AXLE 2 - 15

AXLE NOISE/VIBRATION DIAGNOSIS
INDEX
page page
Driveline Snap........................... 17
Gear and Bearing Noise................... 16
General Information....................... 16Low Speed Knock........................ 17
Vibration............................... 17
GENERAL INFORMATION
Axle bearing problem conditions are usually caused
by:
²Insufficient or incorrect lubricant
²Foreign matter/water contamination
²Incorrect bearing preload torque adjustment
²Incorrect backlash (to tight)
When serviced, the bearings must be cleaned thor-
oughly. They should be dried with lint-free shop tow-
els.Never dry bearings with compressed air.
This will overheat them and brinell the bearing
surfaces. This will result in noisy operation after
repair.
Axle gear problem conditions are usually the result
of:
²Insufficient lubrication
²Incorrect or contaminated lubricant
²Overloading (excessive engine torque) or exceeding
vehicle weight capacity
²Incorrect clearance or backlash adjustment
Insufficient lubrication is usually the result of a
housing cover leak. It can also be from worn axle
shaft or pinion gear seals. Check for cracks or porous
areas in the housing or tubes.
Using the wrong lubricant will cause overheating
and gear failure. Gear tooth cracking and bearing
spalling are indicators of this.
Axle component breakage is most often the result
of:
²Severe overloading
²Insufficient lubricant
²Incorrect lubricant
²Improperly tightened components
Overloading occurs when towing heavier than rec-
ommended loads. Component breakage can occur
when the wheels are spun excessively. Incorrect lu-
bricant quantity contributes to breakage. Loose dif-
ferential components can also cause breakage.
Incorrect bearing preload or gear backlash will not
result in component breakage. Mis-adjustment will
produce enough noise to cause service repair before a
failure occurs. If a mis-adjustment condition is not
corrected, component failure can result.
Excessive bearing preload may not be noisy. This
condition will cause high temperature which can re-
sult in bearing failure.
GEAR AND BEARING NOISE
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant. Incorrect backlash, tooth contact, or worn/dam-
aged gears can cause noise.
Gear noise usually happens at a specific speed
range. The range is 30 to 40 mph, or above 50 mph.
The noise can also occur during a specific type of
driving condition. These conditions are acceleration,
deceleration, coast, or constant load.
When road testing, accelerate the vehicle to the
speed range where the noise is the greatest. Shift
out-of-gear and coast through the peak-noise range.
If the noise stops or changes greatly, check for insuf-
ficient lubricant. Incorrect ring gear backlash, or
gear damage can cause noise changes.
Differential side and pinion gears can be checked
by turning the vehicle. They usually do not cause
noise in straight-ahead driving. These gears are
loaded during vehicle turns. If noise does occur dur-
ing vehicle turns, the side or pinion gears could be
worn or damaged. A worn pinion gear mate shaft can
also cause a snapping or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion gear bear-
ings can all produce noise when worn or damaged.
Bearing noise can be either a whining, or a growling
sound.
Pinion gear bearings have a constant-pitch noise.
This noise changes only with vehicle speed. Pinion
bearing noise will be higher because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs the pinion rear bearing is
the source of the noise. If the bearing noise is heard
during a coast, front bearing is the source.
Worn, damaged differential bearings usually pro-
duce a low pitch noise. Differential bearing noise is
similar to pinion bearing. The pitch of differential
bearing noise is also constant and varies only with
vehicle speed.
Axle shaft bearings produce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
2 - 16 FRONT SUSPENSION AND AXLEJ

level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by a worn
U-joint or by worn side-gear thrust washers. A worn
pinion gear shaft bore will also cause low speed
knock.
VIBRATION
Vibration at the rear of the vehicle is usually
caused by a:
²Damaged drive shaft
²Missing drive shaft balance weight
²Worn, out-of-balance wheels
²Loose wheel lug nuts
²Worn U-joint
²Loose spring U-bolts
²Loose/broken springs
²Damaged axle shaft bearings
²Loose pinion gear nut
²Excessive pinion yoke run out
²Bent axle shaft
Check for loose or damaged front-end components
or engine/transmission mounts. These componentscan contribute to what appears to be a rear-end vi-
bration. Do not overlook engine accessories, brackets
and drive belts.
All driveline components should be examined be-
fore starting any repair.
Refer to Group 22ÐTires And Wheels for addi-
tional information involving vibration diagnosis.
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged), can be caused by:
²High engine idle speed
²Loose engine/transmission/transfer case mounts
²Worn U-joints
²Loose spring mounts
²Loose pinion gear nut and yoke
²Excessive ring gear backlash
²Excessive differential side gear-to-case clearance
The source of a snap or a clunk noise can be deter-
mined with the assistance of a helper. Raise the ve-
hicle on a hoist with the wheels free to rotate.
Instruct the helper to shift the transmission into
gear. Listen for the noise, a mechanics stethoscope is
helpful in isolating the source of a noise.
JFRONT SUSPENSION AND AXLE 2 - 17

MODEL 30 AXLE AND TUBE AXLE (2WD)
INDEX
page page
Axle Bushing Replacement................. 32
Axle Shaft Ð Cardan U-Joint................ 25
Axle Specifications....................... 46
Backlash and Contact Pattern Analysis........ 44
Cleaning/Inspection....................... 35
Differential and Pinion Measurement.......... 38
Differential Assembly...................... 36
Differential Disassembly.................... 34
Differential Installation..................... 43
Differential Removal...................... 32
Differential Shim Pack Measurement and Adjustment.42
Drive Axle Assembly ReplacementÐXJ Vehicles . 21
Drive Axle Assembly ReplacementÐYJ Vehicles . 21Final Assembly.......................... 44
Hub Bearing and Axle Shaft................ 24
Information............................. 20
Inner Axle Shaft Oil Seal Replacement........ 33
Lubricant Change........................ 22
Lubricant Specifications.................... 20
Pinion Gear Assembly/Installation............ 40
Pinion Gear Depth Information.............. 37
Pinion Removal/Disassembly................ 34
Pinion Seal Replacement.................. 23
Steering Knuckle and Ball Studs............. 30
Vacuum Disconnect Axle Ð YJ Vehicles....... 26
INFORMATION
The housing for Model 30 front axles consists of an
iron center casting (differential housing) with axle
shaft tubes extending from either side. The tubes are
pressed into and welded to the differential housing to
form a one-piece axle housing.
The integral type housing, hypoid gear design has
the centerline of the pinion set above the centerline
of the ring gear.
The axle has a fitting for a vent hose used to re-
lieve internal pressure caused by lubricant vaporiza-
tion and internal expansion.
The axles are equipped with semi-floating axle
shafts, meaning that loads are supported by the hub
bearings. The axle shafts are retained by nuts at the
hub bearings. The hub bearings are bolted to the
steering knuckle at the outboard end of the axle tube
yoke. The hub bearings are serviced as an assembly.
The axles are equipped with ABS brake sensors.
The sensors are attached to the knuckle assemblies
and tone rings are pressed on the axle shaft.Use
care when removing axle shafts as NOT to dam-
age the tone wheel or the sensor.
The stamped steel cover provides a means for in-
spection and servicing the differential.
The Model 30 axle has the assembly part number
and gear ratio listed on a tag. The tag is attached to
the housing cover. Build date identification codes are
stamped on the axle shaft tube cover side.
The differential case is a one-piece design. The dif-
ferential pinion mate shaft is retained with a roll
pin. Differential bearing preload and ring gear back-
lash is adjusted by the use of shims (select thick-
ness). The shims are located between the differential
bearing cones and case. Pinion bearing preload is set
and maintained by the use of collapsible spacer.
PINION GEAR DEPTH MEASUREMENT WITH
PINION GAUGE SET 6774, Pinion Block 6733 and
Dial Indicator C-3339 is performed when;²Axle/differential housing is being replaced
²Original pinion depth shim pack is lost or mis-
placed
²Replacing the differential case
²Original differential bearing shim pack is lost or
misplaced
COMMAND-TRACÐYJ VEHICLES
The Command-Trac system is a vacuum disconnect
axle. The system has a two-piece axle shaft coupled
together by a shift collar. For two-wheel drive oper-
ation, the vacuum motor and shift fork disengages
the axle shaft splines. For four-wheel drive opera-
tion, the vacuum motor and shift fork engages the
splines.
SELEC-TRACÐXJ VEHICLES
The Selec-Trac system is a non-disconnect axle.
Shifting from two-wheel to four-wheel drive is at the
transfer case.
For XJ vehicles equipped withSelec-Tracand
ABS brake system, refer to Group 5ÐBrakes for ad-
ditional service information.
LUBRICANT SPECIFICATIONS
Multi-purpose, hypoid gear lubricant should be
used for Model 30 axles. The lubricant should have
MIL-L-2105C and API GL 5 quality specifications.
MOPARtHypoid Gear Lubricant conforms to both of
these specifications.
²The factory fill for the Model 30 axle is SAE 75W
gear lubricant.Do not use heavier weight lubri-
cant, this will cause axle engagement difficulties.
²The factory installed lubricant quantity for the
NON-DISCONNECT TYPE AXLE is 5061 fluid oz..
²The factory installed lubricant quantity for the
VACUUM-DISCONNECT TYPE AXLE is 5661 fluid
oz..
2 - 20 FRONT SUSPENSION AND AXLEJ

Refer to Group 0, Lubrication and Maintenance for
additional information regarding temperature range,
viscosity and fluid level.
CAUTION: If the axle is submerged in water, the lu-
bricant must be replaced immediately to avoid the
possibility of premature axle failure.
DRIVE AXLE ASSEMBLY REPLACEMENTÐXJ
VEHICLES
REMOVAL
(1) Raise the vehicle and position support stands
under the frame rails slightly in behind the lower
suspension arm frame brackets.
(2) Remove the front wheels.
(3) Remove the brake components and ABS brake
sensor (if equipped). Refer to Group 5ÐBrakes.
(4) On 4WD vehicles, disconnect the axle vent
hose.
(5) On 4WD vehicles, mark the drive shaft yoke
and axle pinion yoke for alignment reference. Discon-
nect the drive shaft from the axle.
(6) Disconnect the stabilizer bar link at the axle
bracket.
(7) Disconnect the shock absorbers from axle
bracket.
(8) Disconnect the track bar from the axle bracket.
(9) Disconnect the tie rod and drag link from the
steering knuckle. Disconnect the steering dampener
from the axle bracket.
(10) Support the axle with a hydraulic jack under
the differential.
(11) Disconnect the upper and lower suspension
arms from the axle bracket.
(12) Lower the jack enough to remove the axle.
The coil springs will drop with the axle.
(13) Remove the coil springs from the axle bracket.
INSTALLATION
CAUTION: All suspension components that use rub-
ber bushings should be tightened with the vehicle
at the ride height. It is important to have the
springs supporting the weight of the vehicle when
the fasteners are torqued. If the springs are not at
their normal ride position, vehicle ride comfort
could be affected along with premature rubber
bushing wear. Rubber bushings must never be lu-
bricated.
(1) Install the springs and retainer clip. Tighten
the retainer bolts to 21 Nzm (16 ft. lbs.) torque.
(2) Support the axle on a hydraulic jack under the
differential. Position the axle under the vehicle.
(3) Raise the axle with a floor jack and align it
with the spring pads.(4) Position the upper and lower suspension arm at
the axle bracket. Install bolts and nuts finger
tighten.
(5) Connect the track bar to the axle bracket and
install the bolt.Do not tighten at this time.
It is important that the springs support the
weight of the vehicle when the track bar is con-
nected. If the springs are not at their usual po-
sition, the vehicle ride comfort could be affected.
(6) Install the shock absorber and tighten the bolt
to 19 Nzm (14 ft. lbs.) torque.
(7) Install the stabilizer bar link to the axle
bracket. Tighten the nut to 95 Nzm (70 ft. lbs.)
torque.
(8) Install the drag link and tie rod to the steering
knuckles and tighten the nuts to 47 Nzm (35 ft. lbs.)
torque. Install the steering dampener to the axle
bracket and tighten the nut to 75 Nzm (55 ft. lbs.)
torque.
(9) Install the brake components and ABS brake
sensor (if equipped). Refer to Group 5ÐBrakes.
(10) On 4WD vehicles, connect the vent hose to the
tube fitting.
(11) On 4WD vehicles, align the reference marks
and connect the drive shaft to the axle yoke. Tighten
the U-joint clamp bolts to 19 Nzm (14 ft. lbs.) torque.
(12) Check differential lubricant and add if neces-
sary.
(13) Install the wheel and tire assemblies.
(14) Remove the supports and lower the vehicle.
(15) Tighten the upper suspension arm nuts to 75
Nzm (55 ft. lbs.) torque. Tighten the lower suspension
arm nuts to 115 Nzm (85 ft. lbs.) torque.
(16) Tighten the track bar bolt at the axle bracket
to 100 Nzm (74 ft. lbs.) torque.
(17) Check the front wheel alignment.
DRIVE AXLE ASSEMBLY REPLACEMENTÐYJ
VEHICLES
REMOVAL
(1) Raise the vehicle and position support stands
under the frame rails slightly behind the spring
frame brackets.
(2) Remove the front wheels.
(3) Remove the brake components and ABS brake
sensor (if equipped). Refer to Group 5ÐBrakes.
(4) Disconnect the axle vent hose and axle shift
motor vacuum harness.
(5) Mark the drive shaft yoke and axle pinion yoke
for alignment reference. Disconnect the drive shaft
from the axle.
(6) Disconnect the stabilizer bar link at the axle
bracket.
(7) Disconnect the shock absorbers from axle
bracket.
(8) Disconnect the track bar from the axle bracket.
JFRONT SUSPENSION AND AXLE 2 - 21

(9) Disconnect the tie rod from the steering
knuckle. Disconnect the steering dampener from the
axle bracket.
(10) Support the axle with a hydraulic jack under
the differential. Raise the axle just enough to relieve
the axle weight from the springs.
(11) Remove the spring U-bolts from the plate
brackets.
(12) Loosen BUT DO NOT REMOVE the bolts that
attach the spring rear pivot at the frame rail brack-
ets. This will allow the springs to pivot without bind-
ing on the bushings.
(13) Disconnect shackle from the springs and lower
the springs to the surface.
(14) Lower the jack enough to remove the axle.
INSTALLATION
CAUTION: All suspension components that use rub-
ber bushings should be tightened with the vehicle
at the normal height. It is important to have the
springs supporting the weight of the vehicle when
the fasteners are torqued. If the springs are not at
their normal ride position, vehicle ride comfort
could be affected along with premature rubber
bushing wear. Rubber bushings must never be lu-
bricated.
(1) Support the axle on a hydraulic jack under the
differential. Position the axle under the vehicle.
(2) Raise the springs and install the spring shackle
bolts.Do not tighten at this time.
(3) Lower the axle and align the spring center
bolts with the locating holes in the axle pads and
plate brackets.
(4) Install the spring U-bolts through the plate
brackets and tighten to 122 Nzm (90 ft. lbs.) torque.
(5) Connect the track bar to the axle bracket and
install the bolt.Do not tighten at this time.
It is important that the springs support the
weight of the vehicle when the track bar is con-
nected. If the springs are not at their usual po-
sition, the vehicle ride comfort could be affected.
(6) Install the shock absorber and tighten the nut
to 61 Nzm (45 ft. lbs.) torque.
(7) Install the stabilizer bar link to the axle
bracket. Tighten the nut to 61 Nzm (45 ft. lbs.)
torque.
(8) Install the tie rod to the steering knuckles and
tighten the nuts to 47 Nzm (35 ft. lbs.) torque. Install
the steering dampener to the axle bracket and
tighten the bolt to 75 Nzm (55 ft. lbs.) torque.
(9) Install the brake components and ABS brake
sensor (if equipped). Refer to Group 5ÐBrakes.
(10) Connect the vent hose to the tube fitting and
axle shift motor vacuum harness.(11) Align the reference marks and connect the
drive shaft to the axle yoke. Tighten the U-joint
clamp bolts to 19 Nzm (14 ft. lbs.) torque.
(12) Check differential lubricant and add if neces-
sary.
(13) Install the wheel and tire assemblies.
(14) Remove the supports and lower the vehicle.
(15) Tighten the spring rear pivot bolt/nut to 142
Nzm (105 ft. lbs.) torque. Tighten the spring shackle
bolt/nut to 135 Nzm (100 ft. lbs.) torque.
(16) Tighten the track bar nut at the axle bracket
to 100 Nzm (74 ft. lbs.) torque.
(17) Check the front wheel alignment.
LUBRICANT CHANGE
The gear lubricant will drain quicker if the vehicle
has been recently driven.
(1) Raise and support the vehicle.
(2) Remove the lubricant fill hole plug from the
differential housing cover.
(3) Remove the differential housing cover and
drain the lubricant from the housing.
(4) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.Do not use water,
steam, kerosene or gasoline for cleaning.
(5) Remove the sealant from the housing and cover
surfaces. Use solvent to clean the mating surfaces.
(6) Apply a bead of MOPARtSilicone Rubber Seal-
ant to the housing cover (Fig. 1).Allow the sealant
to cure for a few minutes.
Install the housing cover within 5 minutes af-
ter applying the sealant. If not installed the seal-
ant must be removed and another bead applied.
Fig. 1 Typical Housing Cover With Sealant
2 - 22 FRONT SUSPENSION AND AXLEJ

(9) Remove inboard shoe. Grasp ends of shoe and
tilt shoe outward to release springs from caliper pis-
ton (Fig. 8). Then remove shoe from caliper.
(10) Support caliper on box, mechanics stool, or se-
cure it to nearby suspension part with wire.Do not
allow brake hose to support caliper weight.
(11) Wipe caliper off with shop rags or towels.Do
not use compressed air. Compressed air can un-
seat dust boot and force dirt into piston bore.
(12) Inspect condition of caliper piston dust boot
(Fig. 9). Overhaul caliper if there is evidence of leak-
age past piston and dust boot. Then inspect caliper
bushings and boots (Fig. 9). Replace boots if torn or
cut. If bushings or boots are damaged, replace them.
DISC BRAKESHOE INSTALLATION
(1) Clean brakeshoe mounting ledge slide surfaces
of steering knuckle with wire brush. Then apply
light coat of Mopar multi-mileage grease to slide sur-
faces (Fig. 10).
(2) Lubricate caliper mounting bolts and bushings
(Fig. 10). Use GE 661 or Dow 111 silicone grease.(3) Keep new or original brakeshoes in sets.Do
not interchange them.
(4) Install inboard shoe in caliper (Fig. 11). Be
sure shoe retaining springs are fully seated in caliper
piston.
(5) Install outboard shoe in caliper (Fig. 12). Start
one end of shoe in caliper. Rotate shoe downward and
into place until shoe locating lugs and shoe spring
are seated.
(6) Verify that locating lugs on outboard shoe are
seated in caliper (Fig. 6).
(7) Install caliper. Position notches at lower end of
brakeshoes on bottom mounting ledge (Fig. 13). Then
install caliper over rotor and seat upper ends of
brakeshoes on top mounting ledge (Fig. 11).
CAUTION: Before securing the caliper, be sure the
caliper brake hose is not twisted, kinked or touch-
ing any chassis components. Also be sure the hose
is clear of all suspension and steering components.
Loosen and reposition the hose if necessary.
Fig. 7 Removing Outboard Brakeshoe
Fig. 8 Removing Inboard Brakeshoe
Fig. 9 Caliper Dust Boots And Bushing Locations
Fig. 10 Caliper Lubrication Points
5 - 26 BRAKESJ

BATTERY TESTING GENERAL INFORMATION
Before testing a battery, clean the top of the
battery case, posts and cable terminals.
Specific gravity is a ratio of the density of the elec-
trolyte and the density of pure water. The electrolyte
is composed of sulfuric acid and water. Acid makes
up approximately 35% of the electrolyte by weight,
or 24% by volume.
The condition of a battery may be determined from
the results of 2 tests:
²hydrometer test
²ability to supply current (battery load test)
Perform the hydrometer test first. If the specific
gravity is less than 1.235, (with battery at room tem-
perature) the battery must be charged before pro-
ceeding with further testing. A battery that will not
accept a charge is defective and further testing is not
necessary.
Completely discharged batteries may take sev-
eral hours to accept a charge. See Charging
Completely Discharged Battery.
A battery that has been fully charged but does not
pass the battery load test is defective.
A battery is fully charged when:
²all cells are gassing freely during charging
²3 corrected specific gravity tests, taken at 1-hour
intervals, indicate no increase in specific gravity.
ABNORMAL BATTERY DISCHARGING
(1) Corroded battery posts and terminals.
(2) Loose or worn generator drive belt.
(3) Electrical loads that exceed the output of the
charging system due to equipment or accessories in-
stalled after delivery.
(4) Slow driving speeds (heavy traffic conditions)
or prolonged idling with high-amperage draw sys-
tems in use.
(5) Defective circuit or component causing excess
IOD. Refer to Ignition Off Draw Diagnosis in this
group.
(6) Defective charging system.
(7) Defective battery.
HYDROMETER TEST
Before performing a hydrometer test, remove
battery caps and check electrolyte level. Add
distilled water as required.
Before testing, visually inspect battery for any
damage (cracked case or cover, loose post, etc.) that
would cause the battery to be defective. To use the
hydrometer correctly, hold it with the top surface of
the electrolyte at eye level. Refer to manufacturers
instructions for correct use of hydrometer.
Remove only enough electrolyte from the battery to
keep the float off the bottom of the hydrometer bar-
rel with pressure on the bulb released. Exercise care
when inserting the tip of the hydrometer into a cellto avoid damage to the separators. Damaged separa-
tors can cause premature battery failure.
Hydrometer floats are generally calibrated to indi-
cate the specific gravity correctly only at one fixed
temperature, 80ÉF (26.6ÉC). When testing the specific
gravity at any other temperature, a correction factor
is required.
The correction factor is approximately a specific
gravity value of 0.004, referred to as 4 points of spe-
cific gravity. For each 10ÉF above 80ÉF (5.5ÉC above
26.6ÉC), add 4 points. For each 10ÉF below 80ÉF
(5.5ÉC below 26.6ÉC), subtract 4 points. Always cor-
rect the specific gravity for temperature variation.
Test the specific gravity of the electrolyte in each
battery cell.
Example: A battery is tested at 10ÉF (-12.2ÉC) and
has a specific gravity of 1.240. Determine the actual
specific gravity as follows:
²Determine the number of degrees above or below
80ÉF:
80ÉF - 10ÉF = 70ÉF
²Divide the result above by 10:
70ÉF/10 = 7
²Multiply the result from the previous step by the
temperature correction factor (0.004):
7 x 0.004 = 0.028
²The temperature at testing was below 80ÉF, there-
fore the temperature correction is subtracted:
1.240 - 0.028 = 1.212
²The corrected specific gravity is 1.212.
The fully charged battery should have a tempera-
ture corrected specific gravity of 1.260 to 1.290.
If the specific gravity of all cells is above 1.235,
and cell variation is more than 50 points (0.050), it is
an indication that the battery is unserviceable.
If the specific gravity of one or more cells is less
than 1.235, charge the battery at a rate of approxi-
mately 5 amperes. Continue charging until 3 consec-
utive specific gravity tests, taken at 1 hour intervals,
are constant.
If the cell specific gravity variation is more than 50
points (0.050) after the charge period, replace the
battery.
When the specific gravity of all cells is above 1.235
and variation between cells is less than 50 points
(0.050), the battery may be tested under heavy load.
BATTERY OPEN CIRCUIT VOLTAGE TEST
A battery voltage (no load) test will show state of
charge of a battery that will pass the Battery Load
Test described in this section.Before proceeding
with this test or Battery Load Test, completely
charge battery as described in Battery Charging
in this section.
If a battery has a no load voltage reading of 12.4
volts or greater and will not endure a load test, it is
defective and should be replaced. Refer to Group 8B -
JBATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 3