lock JEEP CHEROKEE 1995 Service Repair Manual

(46) Insert lockpin through access hole and into
shift fork (Fig. 66). Then remove easy-out and seat
the pin with pin punch.
(47) Install plug in lockpin access hole.
(48) Install transfer case shift lever and attaching
nut. Tighten nut to 30 Nzm (22 ft. lbs.) torque.
(49) Install detent plunger, detent spring and de-
tent plug in case (Fig. 67).(50) Install front output shaft (Fig. 68).
(51) Install drive chain (Fig. 68). Engage chain
with front output shaft sprocket teeth.
(52) Install drive sprocket (Fig. 68).
(53) Engage drive sprocket teeth with chain. Then
engage sprocket splines with mainshaft splines.
(54) Install drive sprocket snap ring (Fig. 69).
Fig. 66 Installing Low Range Fork Lockpin
Fig. 67 Detent Pin, Spring And Plug Installation
Fig. 68 Drive Chain And Sprocket Installation
Fig. 69 Drive Sprocket Snap Ring Installation
JNP242 TRANSFER CASE 21 - 327

DOORS
INDEX
page page
Door Alignment AdjustmentÐMajor............ 41
Door Alignment AdjustmentÐMinor............ 37
Door Edge Guard/Edge Protector StripÐXJ...... 54
Door External HandleÐXJ................... 48
Door Hinge/Hinge Pin ReplacementÐXJ........ 52
Door Inside Latch Release and Lock RodsÐXJ . . . 50
Door Key Lock CylinderÐXJ................. 47
Door Latch AdjustmentÐXJ.................. 48
Door LatchÐXJ.......................... 49
Door Removal/InstallationÐXJ............... 35
Door Restraint ReplacementÐXJ............. 41
Door Trim PanelÐXJ...................... 31
Door Window Exterior MoldingsÐXJ........... 54
Door Window Glass and Door Opening
Weatherstrip SealsÐXJ................... 55
Front Door Spacer BlocksÐTwo-Door Vehicles . . . 53
Front Door Window Glass RegulatorÐXJ........ 42Front Door Window GlassÐXJ............... 43
Liftgate AdjustmentÐXJ.................... 63
Liftgate HingeÐXJ........................ 60
Liftgate Latch/Key Lock Cylinder/StrikerÐXJ..... 61
Liftgate License Plate Lamp HousingÐXJ....... 65
Liftgate License Plate Screw Anchor and BumperÐXJ.65
Liftgate Opening Weatherstrip SealÐXJ........ 64
Liftgate Support Rod Ball Stud ReplacementÐXJ . 63
Liftgate Support Rod Cylinder DisposalÐXJ...... 63
Liftgate Support Rod CylinderÐXJ............. 62
Liftgate Trim PanelÐXJ..................... 59
LiftgateÐXJ............................. 58
Rear Door Stationary Window GlassÐXJ........ 46
Rear Door Window Glass RegulatorÐXJ........ 44
Rear Door Window GlassÐXJ................ 45
Service Information........................ 30
SERVICE INFORMATION
The door service procedures includes removal, in-
stallation and/or replacement of the following door
components:
²Door handles.²Armrests.
²Trim panels.
²Waterdams.
²Door restraints.
²Front doors.
Fig. 1 Front Door Trim Panel
23 - 30 DOORSÐXJJ

²Rear doors.
²Window glass regulators.
²Key lock cylinders.
²Door half-hinges.
²Liftgate.
²Liftgate hinges.
²Liftgate gas support rod cylinders.
²Rocker panel seals.
²Moldings/weatherstrip seals.DOOR TRIM PANELÐXJ
SERVICE INFORMATION
All attached components can be removed from door
trim panels (Fig. 1 and 2).
REMOVAL
(1) Remove the door inside latch release handle
screws (Fig. 3 and 4).
Fig. 2 Rear Door Trim Panel
Fig. 3 Front Door Inside Latch Release Handle
Fig. 4 Rear Door Inside Latch Release Handle
JDOORSÐXJ 23 - 31

(2) Move the door handle outward and disconnect
the handle-to-latch rods (Fig. 5). For vehicles
equipped with power door locks/windows, disconnect
the wire harness connector (Fig. 6).
(3) Remove the regulator handle (Fig. 7) or, if
equipped, power window switches and bezel.
(4) Remove the armrest lower screws (Fig. 8 and
9).
(5) Pull armrest straight outward from panel and
remove.
Fig. 5 Door Inside Latch Release Rods
Fig. 6 Power Switch Wire Harness Connector
Fig. 7 Window Regulator Handles
Fig. 8 XJ Front Door Armrest Removal/Installation
23 - 32 DOORSÐXJJ

(10) If necessary, remove the storage bin panel and
speaker grille from the front door trim panel (Fig.
16).
(11) If necessary, remove the ash receiver tray
housing from the rear door trim panel (Fig. 17).(12) If necessary, replace the armrest upper re-
tainer clip, retainer clip anchor and armrest support
bracket (Fig. 18 and 19).
INSTALLATION
(1) If door waterdam was removed, apply sealant
to the edges before installing.
Fig. 14 Latch Release and Lock Rod Waterdam
Fig. 15 Power Switch Waterdam
Fig. 16 Storage Bin Panel and Speaker Grille
Fig. 17 Ash Receiver Tray Housing
Fig. 18 Armrest Upper Retainer Clip and Anchor
Fig. 19 Armrest Support Bracket
23 - 34 DOORSÐXJJ

(2) Position the waterdam on door inner panel (Fig. 20).
(3) If removed, install the storage bin panel and
speaker grille on the front door trim panel.
(4) If removed, install the ash receiver tray hous-
ing on the rear door trim panel.
(5) Position the trim panel on the door inner panel
and press the retainers inward.
(6) Install the armrest and window glass regulator
handle. Or (if equipped) the power window switches
and bezel. Tighten the armrest screws to 4 Nzm (34
in-lbs) torque.
(7) Connect the rods to the inside latch release han-
dle and install the handle. Tighten the screws to 2 Nzm
(16 in-lbs) torque. For vehicles with power door locks/
windows, connect the wire harness connector.
DOOR REMOVAL/INSTALLATIONÐXJ
REMOVAL
(1) Remove the door restraint (check) retaining pin
(Fig. 1) with a punch.
(2) For vehicles equipped with power windows and
power door locks, remove the trim panel and discon-
nect all components. Slide the wire harness out of
the boot and door (Fig. 2, 3, 4, 5 and 6)
Fig. 1 Door Restraint Retaining Pin
Fig. 20 Waterdam Installation
Fig. 2 Right Front Door Wire Harness Connectors
Fig. 3 Right Front Door Wire Harness ConnectorsÐ
With Security Alarm Switch
JDOORSÐXJ 23 - 35

(3) Remove the window weatherstrip seals from
the door.
(4) Remove the trim panel and waterdam from
door inner panel.
(5) Remove the channel/division bar screws. Drill
out the rivet head to remove it from the inner panel.
(6) Tilt the channel/division bar forward and re-
move it from the door.
(7) Remove the fixed glass support bracket bolts
from the door inner panel reinforcement bracket (Fig.
12).
(8) Remove the fixed glass from the door (Fig. 13).
INSTALLATION
(1) Install the fixed glass in the door, and install
the bolts in the reinforcement and support brackets.
(2) Tighten the bracket retaining bolts to 9 Nzm
(79 in-lbs) torque.
(3) Install the channel/division bar in the door.
(4) Install the channel/division bar screws and
rivet. Tighten the screws to 6 Nzm (5 ft-lbs) torque.
(5) Install the channel and belt weatherstrip seals.(6) Install the beltline molding.
(7) Install the door waterdam and trim panel.
DOOR KEY LOCK CYLINDERÐXJ
REMOVAL
(1) Remove the door trim panel and waterdam.
(2) Disconnect the door latch-to-lock cylinder rod at
the door latch (Fig. 14).
(3) If equipped, disconnect the security alarm
switch connector from the lock cylinder (Fig. 15).
Fig. 12 Fixed Glass Support Bracket Bolts
Fig. 13 Fixed Glass Removal/Installation
Fig. 14 Key Lock Cylinder and Door Latch
Fig. 15 Security Alarm Switch
JDOORSÐXJ 23 - 47

(4) Remove the key lock cylinder retainer clip. Re-
move the lock cylinder, gasket and clip from the door
opening (Fig. 16).
(5) If applicable, remove the door latch-to-lock cyl-
inder rod from the original lock cylinder. Connect it
to the replacement lock cylinder.
INSTALLATION
(1) Position the lock cylinder and gasket in the
door opening. Hold the lock cylinder in the opening
with the retainer clip.
(2) Connect the door latch-to-lock cylinder rod to
the door latch.
(3) If equipped, connect the security alarm switch
connector to the lock cylinder.
(4) Test and, if necessary, adjust the door latch-to-
lock cylinder rod operation.
(5) Install the door trim panel and waterdam.
(6) Adjust the door latch as described in DOOR
LATCH ADJUSTMENT.
DOOR LATCH ADJUSTMENTÐXJ
(1) Remove the access hole plug from the latch face
(Fig. 17).
(2) Insert a 5/32-inch wrench through the hole and
into the latch release lever adjustment screw and
loosen.
(3) Press and release the outside door handle latch
release button several times.
(4) Release the button and tighten adjustment
screw to 3 Nzm (30 in-lbs) torque.
(5) Test the release handle button and key lock cyl-
inder for proper latch release.
(6) Install the door waterdam and trim panel.
DOOR EXTERNAL HANDLEÐXJ
REMOVAL
(1) Remove the door trim panel and waterdam.
(2) Remove the access hole cover and remove the
door handle nuts (Fig. 18).
(3) Disconnect the handle-to-latch rod from the
handle latch release lever arm.
(4) Remove the nuts and handle from the door.
(5) Remove the gaskets from the door outer panel
surface, if necessary.
INSTALLATION
(1) Assemble the replacement door handle, if nec-
essary (Fig. 19). Apply silicone spray lubricant to the
components.
Fig. 16 Key Lock Cylinder Removal/Installation
Fig. 17 Door Latch Adjustment
Fig. 18 Door External Handle Removal/Installation
23 - 48 DOORSÐXJJ

(2) If the original gaskets were removed, position
the replacement gaskets on the handle. Position the
handle on the door outer panel.
(3) Install and tighten the handle nuts.
(4) Connect the latch-to-handle rod to the handle
latch release lever arm.
(5) Install the door waterdam and trim panel.
(6) Adjust the door latch as described in DOOR
LATCH ADJUSTMENT.
DOOR LATCHÐXJ
REMOVAL
(1) Remove the access plug located at the upper
end of the door (Fig. 20).
(2) Remove the door trim panel and waterdam.
(3) Remove the door external handle from the door
outer panel.(4) Remove the door latch screws (Fig. 21).
(5) Remove the retainer clip and key lock cylinder
from the door outer panel.
(6) Disconnect all the rods from the door latch (Fig.
22).
Fig. 19 Door Handle Components
Fig. 20 Access Plug
Fig. 21 Door Latch Retaining Screws
Fig. 22 Door Latches
JDOORSÐXJ 23 - 49

(7) Remove the door latch from the door face.
(8) For vehicles equipped with power door locks,
remove the lock motor rivets. Remove the motor and
latch as a unit from the door. Detach the rod and mo-
tor from the latch (Fig. 23).
INSTALLATION
(1) If necessary, install a replacement latch striker
(Fig. 24).
(2) For vehicles equipped with power door locks,
attach the rod and lock motor to the latch. Attach the
lock motor to the door panel with either rivets or
with bolts and nuts (Fig. 23).
(3) Install the door latch at the door face and con-
nect all the rods to the latch.
(4) Install the latch screws. Tighten the screws to
9Nzm (77 in-lbs) torque.
(5) Install the external handle.
(6) Install the latch-to-door handle rod.
(7) Install the key lock cylinder and retainer clip.
(8) Install the door waterdam and trim panel.
(9) Install the door access plug.(10) Adjust the door latch as described in DOOR
LATCH ADJUSTMENT.
DOOR INSIDE LATCH RELEASE AND LOCK
RODSÐXJ
REMOVAL
(1) Remove the door inside latch release handle
screws (Fig. 1 and 2).
Fig. 23 Door Lock Motor
Fig. 24 Door Latch Striker Removal/Installation
Fig. 1 Front Door Inside Latch Release Handle
Fig. 2 Rear Door Inside Latch Release Handle
23 - 50 DOORSÐXJJ