JEEP CHEROKEE 1995 Service Repair Manual

LIFTGATEÐXJ
The liftgate components are illustrated in Figure 1.
REMOVAL
WARNING: DO NOT DISCONNECT THE SUPPORT
ROD CYLINDERS WITH THE LIFTGATE CLOSED.
THE SUPPORT ROD PISTONS ARE OPERATED BY
HIGH PRESSURE GAS. THIS COULD CAUSE DAM-
AGE AND/OR PERSONAL INJURY IF THEY ARE RE-
MOVED WHILE PISTONS ARE COMPRESSED.
(1) Open the liftgate.
(2) Remove the liftgate trim panel (Fig. 2).
(3) Remove the retainer clips that secure the sup-
port rod cylinders to the ball studs (Fig. 3).
(4) Remove the support rod cylinders from the ball
studs.
(5) Remove the screws and the wire harness trim
cover from the liftgate header (Fig. 4).
Fig. 1 Liftgate Components
Fig. 2 Liftgate Trim Panel
23 - 58 DOORSÐXJJ

(6) Disconnect the connectors and remove the wire
harness from the liftgate (Fig. 5).
(7) Remove the hinge-to-liftgate screws.
(8) Remove the liftgate from the vehicle.
INSTALLATION
(1) Position and support the liftgate at the opening
in the body and install the hinge-to-liftgate screws.
(2) Adjust the liftgate to fit properly in the body
opening. Refer to Liftgate Adjustment.
(3) Tighten the hinge-to-liftgate screws to 9 Nzm(7
ft-lbs) torque.
(4) Connect the liftgate rod cylinders to the ball
studs and install the rod cylinder retainer clips.
(5) Insert and connect the wire harness connectors.
(6) Position the wire harness trim cover on the
header and install the screws. Tighten the screws to
1Nzm (11 in-lbs) torque.(7) Install the trim panel.
LIFTGATE TRIM PANELÐXJ
REMOVAL
(1) Remove the screws that attach the panel upper
sides to the liftgate.
(2) Use a trim stick to detach the panel retainers
from the liftgate.
(3) Remove the trim panel from the liftgate.
(4) If necessary, drill-out the rivet heads and re-
move the trim panel strip from the liftgate (Fig. 6).
INSTALLATION
(1) If removed, install the trim panel retainer strip
on the liftgate with replacement rivets.
(2) Position the trim panel on liftgate.
Fig. 3 Support Rod Retainer Clip
Fig. 4 Liftgate Wire Harness Trim Cover
Fig. 5 Liftgate Wire Harness and Hinge Screws
Fig. 6 Liftgate Trim Panel Retainer
JDOORSÐXJ 23 - 59

(3) Align the trim panel retainers with the holes in
the liftgate inner panel and force the trim panel in-
ward.
(4) Install the screws to attach the panel upper
sides to the liftgate.
LIFTGATE HINGEÐXJ
REMOVAL
It is not necessary to remove the liftgate to replace
one or both hinges.
(1) Remove the liftgate (headliner) upper trim
molding (Fig. 7).
(2) Remove the hinge-to-roof panel nuts (Fig. 8).
(3) Remove the hinge-to-liftgate screws and remove
the hinge from the liftgate (Fig. 9).
INSTALLATION
(1) Position the gaskets, shim and hinge on the
liftgate and the roof panel (Fig. 10).
(2) Install and tighten hinge-to-roof panel nuts to 9
Nzm (7 ft-lbs) torque.(3) Install the liftgate-to-hinge screws. Tighten
screws to 9 Nzm (7 ft-lbs) torque.
(4) Install the liftgate (headliner) upper trim mold-
ing (Fig. 7).
Fig. 7 Liftgate Upper Trim Molding
Fig. 8 Liftgate Hinge-To-Roof Panel Nuts
Fig. 9 Liftgate Hinges
Fig. 10 Liftgate Hinge, Gaskets and Shim
23 - 60 DOORSÐXJJ

LIFTGATE LATCH/KEY LOCK CYLINDER/STRIKERÐ
XJ
REMOVAL
(1) Raise the liftgate and remove the latch screws
(Fig. 11).
(2) Disconnect the rod from the latch (Fig. 12).
(3) Remove the latch from the liftgate (Fig. 13).
(4) Drill-out the rivet heads and remove the lock
solenoid from liftgate (Fig. 14).(5) Remove the lock cylinder retainer clip (Fig. 15).
(6) Remove the key lock cylinder.
Fig. 11 Liftgate Latch Screws
Fig. 12 Latch and Key Lock Cylinder
Fig. 13 Liftgate Latch and Solenoid
Fig. 14 Liftgate Lock Solenoid
Fig. 15 Liftgate Key Lock Cylinder
JDOORSÐXJ 23 - 61

(7) Remove the latch striker screws from the scuff
plate and cross sill (Fig. 16)
(8) Remove the striker and shim from the retainer.
INSTALLATION
(1) Install the key lock cylinder. Secure the lock
cylinder with the retainer clip (Fig. 17).
(2) Position the latch in the liftgate.
(3) Connect the latch rod.
(4) Install and tighten the latch screws to 12 Nzm
(110 in-lbs) torque.
(5) Install the striker retainer, shim, striker and
screws in the scuff plate cross sill.
LIFTGATE SUPPORT ROD CYLINDERÐXJ
REMOVAL
WARNING: DO NOT REMOVE A SUPPORT ROD
CYLINDER WITH THE LIFTGATE CLOSED. EACH
SUPPORT ROD PISTON IS OPERATED BY HIGH
PRESSURE GAS. IT CAN CAUSE DAMAGE AND/OR
PERSONAL INJURY IF IT IS REMOVED WITH THE
PISTON COMPRESSED. DO NOT ATTEMPT TO DIS-
ASSEMBLE OR REPAIR A SUPPORT ROD CYLIN-
DER.
(1) Open the liftgate.
(2) Support the liftgate in the open position.
(3) Remove the clips that attach the support rod
and cylinder to the ball studs (Fig. 1).
(4) Disconnect the support rod and cylinder from
the ball studs and remove the cylinder from vehicle
(Fig. 2).
(5) De-pressurize the original rod cylinder before
disposal. Refer to the procedure below.
INSTALLATION
(1) Connect the replacement support rod and cylin-
der to the ball studs.
(2) Secure the support rod and cylinder to the ball
studs with the retainer clips.
(3) Remove the support from the liftgate and test
the operation of the support rod.
Fig. 16 Liftgate Latch Striker
Fig. 17 Liftgate Key Lock Cylinder and Latch
Fig. 1 Support Rod Retainer Clip
23 - 62 DOORSÐXJJ

LIFTGATE SUPPORT ROD CYLINDER DISPOSALÐ
XJ
WARNING: SAFETY GOGGLES MUST BE WORN
DURING THE DISPOSAL PROCEDURE. THE HIGH
PRESSURE GAS CHARGE IN THE SUPPORT ROD
CYLINDERS WILL BE RELEASED DURING THE
PROCEDURE.
(1) Remove the support rod cylinder(s) from the
liftgate.
(2) Position the support rod cylinder horizontally
in a vise and clamp the cylinder securely.
(3) Wrap the cylinder with 4-5 layers of shop tow-
els.
(4) Measure 1 and 1/2 inches inward from the end
of the cylinder. Mark this location on the towels with
chalk. The cylinder will be punctured at this location
to release the gas charge.
(5) Use a punch and hammer to puncture cylinder.
Force the punch through towels and into the cylinder
with a hammer. Continue striking the punch until
the gas begins to escapebut do not remove the
punch.
(6) Hold the towels and punch in position until all
the gas has escaped. Complete de-pressurization will
require about 4 to 10 seconds. After all the gas has
escaped, slowly remove the punch.
(7) Hold a towel over the hole in cylinder and press
the support rod piston all the way into the cylinder
to purge remaining oil.
(8) Remove the support rod cylinder from the vise
and discard it.
(9) If both support rod cylinders are being re-
placed, repeat this procedure for the remaining cylin-
der.
LIFTGATE SUPPORT ROD BALL STUD
REPLACEMENTÐXJ
REMOVAL
(1) Open the liftgate.
(2) Support the liftgate in the open position.
(3) Remove the retainer clip that attaches the sup-
port rod and cylinder to the ball stud.
(4) Disconnect the support rod from the ball stud.
(5) Remove the ball stud from the liftgate with a
T-30 Torx-head socket wrench (Fig. 3).
INSTALLATION
(1) Install the replacement ball stud in the liftgate
with a T-30 Torx-head socket wrench. Tighten the
ball stud to 7 Nzm (62 in-lbs) torque.
(2) Connect the support rod to the ball stud.
(3) Secure the support rod to the ball stud with the
clip.
(4) Remove the support from the liftgate and test
the operation of support rod.
LIFTGATE ADJUSTMENTÐXJ
SERVICE INFORMATION
The position of the liftgate can be adjusted upward
or downward, and inward or outward by the use of
hinge shims. The liftgate stop bumpers must also be
adjusted if liftgate hinges are adjusted. The inward/
outward position of each stop bumper is adjusted by
the use of shims (Fig. 4).
ADJUSTMENT PROCEDURE
(1) To move the position of the liftgate inward or
outward, remove or add shims between the hinge-
halves and liftgate.
(2) To move the position of the liftgate upward or
downward, remove or add shims between the hinge-
halves and roof panel.
Fig. 2 Support Rod, Retainer Clips and Ball Studs
Fig. 3 Support Rod Ball Studs
JDOORSÐXJ 23 - 63

(3) To move the position of liftgate stop bumpers
inward or outward, remove or add shims between the
stop bumper screws and anchors (Fig. 5).
LIFTGATE OPENING WEATHERSTRIP SEALÐXJ
REMOVAL
(1) Pull the seal away from the flange around the
perimeter of liftgate opening and remove it (Fig. 6
and 7).
(2) Clean the flange as necessary.
INSTALLATION
(1) Position weatherstrip seal in the opening with
the left end of the seal at the opening centerline. In-
stall the seal in a clockwise direction.
(2) Move to the left and mate the seal with the bot-
tom-left flange (Fig. 6).
(3) Move upward and mate the seal with the left-
side flange.
(4) Move to the right and mate the seal with the
top-left roof flange.
(5) Seat the installed part of the seal with a roller.
Move the roller from the left-bottom end of seal to
the top-left half of the seal.
(6) Move to the right and mate the seal with the
top-right roof flange.
Fig. 4 Liftgate Adjustment Shims
Fig. 5 Stop Bumper Screw Anchors
Fig. 6 Liftgate Opening Weatherstrip Seal Removal/
Installation
Fig. 7 Liftgate Opening Weatherstrip Seal
23 - 64 DOORSÐXJJ

(7) Move downward and mate the seal with the
right-side flange.
(8) Move to the left and mate the seal with the bot-
tom-right flange.
(9) Center and butt seal the ends together at the
centerline.
(10) Seat the remaining part of the seal with a
roller. Move the roller the from top-left half of the
seal to the right-bottom end of the seal.
LIFTGATE LICENSE PLATE LAMP HOUSINGÐXJ
REMOVAL
(1) Remove the lamp housing screws from the lift-
gate (Fig. 8).
(2) Disconnect bulb socket from lamp housing.
(3) Remove the housing from the liftgate.
INSTALLATION
(1) Position the lamp housing at the liftgate.
(2) Connect the bulb socket to the lamp housing.
(3) Install the lamp housing retaining screws in
the liftgate.
LIFTGATE LICENSE PLATE SCREW ANCHOR AND
BUMPERÐXJ
ANCHOR REPLACEMENT
(1) Remove the screw from the anchor (Fig. 9).
(2) Pry the anchor from the liftgate.
(3) Compress the ends and insert the anchor in the
liftgate hole.
(4) Install the screw in the anchor.
BUMPER REPLACEMENT
(1) Pry the bumper from the liftgate.
(2) Insert the replacement screw anchor in the lift-
gate hole.
Fig. 8 Liftgate License Plate Lamp Housing
Fig. 9 Liftgate License Plate Screw Anchors and
Bumpers
JDOORSÐXJ 23 - 65

STATIONARY WINDOW GLASS
INDEX
page page
Interior Rearview MirrorÐXJ Removal and
Installation............................. 66
Interior Rearview Mirror Support Bracket
ReplacementÐXJ Preparation and Installation . . . 66
Description and Operation.......... ..........67
InstallationÐShort Method.......... ..........69
InstallationÐExtended Method........ ........71Rear Door Stationary Window Glass...... ......72
Rear Quarter Vent Window GlassÐXJ Removal
and Installation............. .............73
Rear Quarter Window Glass/Rear Quarter Plastic
InsertÐXJ Removal and Installation..... .....73
INTERIOR REARVIEW MIRRORÐXJ
MIRROR REMOVAL
(1) Loosen the mirror base-to-bracket setscrew
(Fig. 1).
(2) Slide the mirror base upward and off the sup-
port bracket (Fig. 2).
MIRROR INSTALLATION
(1) Slide the mirror base onto the support bracket
(Fig. 2).
CAUTION: Do not over-tighten setscrew because
glass chipping or breakage could result.
(2) Tighten the setscrew to 1 Nzm (9 in-lbs) torque
(Fig. 1).
INTERIOR REARVIEW MIRROR SUPPORT
BRACKET REPLACEMENTÐXJ
PREPARATION
(1) Mark reference lines for the mirror support bracket
on the outside of windshield glass with a wax pencil.
(2) If the vinyl pad remained on the windshield
glass, soften and remove it with a heat gun.
(3) Clean the support bracket surface area on the
glass. Use a mild abrasive cleaning powder on a cloth
saturated with isopropyl (rubbing) alcohol.
(4) Lightly sand the contact surface on the support
bracket with fine grit sandpaper. Wipe bracket con-
tact surface clean with a paper towel and alcohol.
Fig. 1 Interior Rearview Mirror Setscrew
Removal/Installation
Fig. 2 Interior Rearview Mirror Removal/Installation
23 - 66 STATIONARY WINDOW GLASSÐXJJ1995 Jeep Cherokee/Wrangler
Publication No. 81-370-5146
TSB 26-05-95 July, 1995

INSTALLATION
(1) Apply adhesive to the act surface on the sup-
port bracket according as follows:
²crush the vial in the plastic housing of the accel-
erator to saturate the felt applicator.
²remove the paper sleeve.
²apply a generous amount of accelerator to the con-
tact surface on the mirror support bracket.
²do not touch the support bracket contact surface
after the accelerator has been applied.
²
allow the accelerator to dry for at least five minutes.
and
(2) Apply accelerator to the support bracket con-
tact surface on the windshield glass. Allow the accel-
erator to dry for one minute.
(3) Install the mirror bracket on the windshield
glass as follows:
²apply one drop of adhesive at the center of support
bracket contact surface on windshield glass.
²immediately apply an even coat of adhesive to the
contact surface on the support bracket.
²align the support bracket with the position refer-
ence lines on the windshield glass, then
²press and hold the support bracket in-place for at
least one minute.
Ensure that the mirror support bracket is
correctly aligned because the adhesive will
cure rapidly.
(4) Allow the adhesive to cure for 8-10 minutes,
then remove any residue adhesive with an alcohol-
dampened cloth.
(5) Allow the adhesive to cure for an additional
8-10 minutes before installing the mirror base on the
support bracket.
DESCRIPTION AND OPERATION
SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR THE URE-
THANE ADHESIVE TO CURE. IF IT IS NOT CURED,
THE WINDSHIELD MAY NOT PERFORM PROPERLY
IN AN ACCIDENT.
URETHANE ADHESIVES ARE APPLIED AS A SYS-
TEM. USE GLASS CLEANER, GLASS PREP SOL-
VENT, GLASS PRIMER, AND PINCHWELD (FENCE)
PRIMER PROVIDED BY THE ADHESIVE MANUFAC-
TURER. IF NOT, STRUCTURAL INTEGRITY COULD
BE COMPROMISED.
BE SURE TO REFER TO THE URETHANE MANU-
FACTURER'S DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE AF-
TER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY, USE THEM IN A WELL VENTI-
LATED AREA.
SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED, OR PERSONAL INJURY MAY
RESULT.
ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted or trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
It is difficult to salvage a windshield during the re-
moval operation. The windshield is part of the struc-
tural support for the roof. The urethane bonding
used to secure the windshield to the fence is difficult
to cut or clean from any surface. If the moldings are
set in urethane, it would also be unlikely they could
be salvaged. Before removing the windshield, check
the availability of the windshield and moldings from
the parts supplier.
JSTATIONARY WINDOW GLASSÐXJ 23 - 671995 Jeep Cherokee/Wrangler
Publication No. 81-370-5146
TSB 26-05-95 July, 1995