rings JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual

INTERNATIONAL SYMBOLS
DESCRIPTION
DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid inspection and fill locations (Fig. 1).
PARTS & LUBRICANT
RECOMMENDATION
STANDARD PROCEDURE - PARTS &
LUBRICANT RECOMMENDATIONS
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 2) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letter
ªGº. Chassis lubricant is identified by the latter ªLº.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
When service is required, DaimlerChrysler Corpo-
ration recommends that only Mopartbrand parts,
lubricants and chemicals be used. Mopar provides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
FLUID TYPES
DESCRIPTION
DESCRIPTION - ENGINE COOLANT
ETHYLENE-GLYCOL MIXTURES
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
The required ethylene-glycol (antifreeze) and water
mixture depends upon the climate and vehicle oper-
ating conditions. The recommended mixture of 50/50
ethylene-glycol and water will provide protection
against freezing to -37 deg. C (-35 deg. F). The anti-
freeze concentrationmust alwaysbe a minimum of
44 percent, year-round in all climates.If percentage
is lower than 44 percent, engine parts may be
eroded by cavitation, and cooling system com-
ponents may be severely damaged by corrosion.
Maximum protection against freezing is provided
with a 68 percent antifreeze concentration, which
prevents freezing down to -67.7 deg. C (-90 deg. F). A
higher percentage will freeze at a warmer tempera-
ture. Also, a higher percentage of antifreeze can
cause the engine to overheat because the specific
heat of antifreeze is lower than that of water.
Use of 100 percent ethylene-glycol will cause for-
mation of additive deposits in the system, as the cor-
rosion inhibitive additives in ethylene-glycol require
the presence of water to dissolve. The deposits act as
insulation, causing temperatures to rise to as high as
149 deg. C (300) deg. F). This temperature is hot
enough to melt plastic and soften solder. The
increased temperature can result in engine detona-
tion. In addition, 100 percent ethylene-glycol freezes
at 22 deg. C (-8 deg. F ).
PROPYLENE-GLYCOL MIXTURES
It's overall effective temperature range is smaller
than that of ethylene-glycol. The freeze point of 50/50
propylene-glycol and water is -32 deg. C (-26 deg. F).
5 deg. C higher than ethylene-glycol's freeze point.
The boiling point (protection against summer boil-
over) of propylene-glycol is 125 deg. C (257 deg. F )
at 96.5 kPa (14 psi), compared to 128 deg. C (263
deg. F) for ethylene-glycol. Use of propylene-glycol
can result in boil-over or freeze-up on a cooling sys-
tem designed for ethylene-glycol. Propylene glycol
also has poorer heat transfer characteristics than
ethylene glycol. This can increase cylinder head tem-
peratures under certain conditions.
Fig. 1 INTERNATIONAL SYMBOLS
Fig. 2 NLGI Symbol
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
0 - 2 LUBRICATION & MAINTENANCEWJ

SUSPENSION
TABLE OF CONTENTS
page page
SUSPENSION
DIAGNOSIS AND TESTING - SUSPENSION
AND STEERING SYSTEM................1WHEEL ALIGNMENT......................3
FRONT.................................6
REAR.................................17
SUSPENSION
DIAGNOSIS AND TESTING - SUSPENSION AND
STEERING SYSTEM
CONDITION POSSIBLE CAUSES CORRECTION
FRONT END NOISE 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
2. Loose or worn steering or
suspension components.2. Tighten or replace components as
necessary.
EXCESSIVE PLAY IN
STEERING1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
2. Loose or worn steering or
suspension components.2. Tighten or replace components as
necessary.
3. Loose or worn steering gear. 3. Adjust or replace steering gear.
FRONT WHEELS SHIMMY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
2. Loose or worn steering or
suspension components.2. Tighten or replace components as
necessary.
3. Tires worn or out of balance. 3. Replace or balance tires.
4. Alignment. 4. Align vehicle to specifications.
5. Leaking steering dampener. 5. Replace steering dampener.
VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
2. Loose or worn steering or
suspension components.2. Tighten or replace components as
necessary.
3. Tire pressure. 3. Adjust tire pressure.
4. Alignment. 4. Align vehicle to specifications.
EXCESSIVE STEERING
EFFORT1. Loose or worn steering gear. 1. Adjust or replace steering gear.
2. Power steering fluid low. 2. Add fluid and repair leak.
3. Column coupler binding. 3. Replace coupler.
4. Tire pressure. 4. Adjust tire pressure.
5. Alignment. 5. Align vehicle to specifications.
WJSUSPENSION 2 - 1

FRONT
TABLE OF CONTENTS
page page
FRONT
DESCRIPTION..........................6
STANDARD PROCEDURE - SERVICE
WARNINGS AND CAUTIONS..............6
SPECIFICATIONS
TORQUE CHART......................7
SPECIAL TOOLS
FRONT SUSPENSION...................8
BUSHINGS
REMOVAL.............................9
INSTALLATION..........................9
HUB / BEARING
DESCRIPTION..........................9
OPERATION............................9
REMOVAL.............................9
INSTALLATION.........................10
KNUCKLE
DESCRIPTION.........................10
OPERATION...........................10
REMOVAL - STEERING KNUCKLE..........10
INSTALLATION.........................10
LOWER BALL JOINT
REMOVAL.............................11
LOWER CONTROL ARM
DESCRIPTION.........................11
OPERATION...........................11
REMOVAL.............................11
INSTALLATION.........................11SHOCK
DESCRIPTION.........................12
OPERATION...........................12
REMOVAL.............................12
INSTALLATION.........................12
SPRING
DESCRIPTION.........................12
OPERATION...........................13
REMOVAL.............................13
INSTALLATION.........................13
STABILIZER BAR
DESCRIPTION.........................14
OPERATION...........................14
REMOVAL.............................14
INSTALLATION.........................14
TRACK BAR
DESCRIPTION.........................14
OPERATION...........................14
REMOVAL.............................14
INSTALLATION.........................14
UPPER BALL JOINT
REMOVAL.............................15
UPPER CONTROL ARM
DESCRIPTION.........................16
OPERATION...........................16
REMOVAL.............................16
INSTALLATION.........................16
FRONT
DESCRIPTION
The front suspension (Fig. 1) is a link/coil design
comprised of :
²Drive axle
²Shock absorbers
²Coil springs
²Upper and lower suspension arms
²Stabilizer bar
²Track bar
²Jounce bumpers
CAUTION: Components attached with a nut and cot-
ter pin must be torqued to specification. Then if the
slot in the nut does not line up with the cotter pin
hole, tighten nut until it is aligned. Never loosen the
nut to align the cotter pin hole.CAUTION: Suspension components with rubber
bushings must be tightened with the vehicle at nor-
mal ride height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort will be affected
and cause premature bushing wear.
STANDARD PROCEDURE - SERVICE
WARNINGS AND CAUTIONS
CAUTION: Suspension components with rubber
bushings must be tightened with the vehicle at nor-
mal ride height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort will be affected
and cause premature bushing wear.
2 - 6 FRONTWJ

SHOCK
DESCRIPTION
The top of the shock absorbers are bolted to the
body. The bottom of the shocks are bolted to the axle
brackets. The standard shocks have conventional
twin tube construction and are low pressure gas
charged. Gas charging prevents cavitation during
rough road operation. Up-Country shocks are mono
tube design and are high pressure gas charged.
OPERATION
The shock absorbers dampen jounce and rebound
motion of the vehicle over various road conditions
and limit suspension rebound travel.
REMOVAL
(1) Remove the nut, retainer and grommet from
the shock stud in the engine compartment (Fig. 8).
(2) Raise and support the front axle.
(3) Remove the lower mounting nuts from the axle
bracket (Fig. 9). Remove the shock absorber.
INSTALLATION
(1) Position the lower retainer and grommet on the
shock stud. Insert the shock absorber through the
shock tower hole.
(2) Install the lower shock studs into the axle
bracket.
(3) Install the mounting nuts and tighten to 28
N´m (250 in. lbs.).
(4) Remove support and lower the vehicle.(5) Install the upper grommet, retainer and nut on
the stud in the engine compartment. Hold the shock
stud witha8mmwrench and tighten the nut to 35
N´m (26 ft. lbs.).SPRING
DESCRIPTION
The coil springs mount up in the wheelhouse which
is part of the unitized body bracket. A rubber dough-
nut isolator is located between the top of the spring
and the body. The bottom of the spring seats on a
axle isolator made of rubber with a steel insert.
Fig. 7 Lower Suspension Arm
1 - LOWER SUSPENSION ARM
2 - FRAME RAIL BRACKET
3 - AXLE BRACKET
Fig. 8 Upper Shock Mounting
1 - RETAINER
2 - STUD
3 - NUT
4 - GROMMET
Fig. 9 Lower Shock Mounting
1 - SHOCK ABSORBER
2 - MOUNTING NUTS
2 - 12 FRONTWJ
LOWER CONTROL ARM (Continued)

OPERATION
The coil springs control ride quality and maintain
proper ride height. The isolators provide road noise
isolation.
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assemblies.
(3) Position a hydraulic jack under the axle to sup-
port it.
(4) Remove shock absorbers lower mounting nuts
from the axle brackets.
(5) Remove the track bar mounting bolt from the
axle bracket.
NOTE: Make sure the lower part of the shock does
not hold tension on the brake lines at the axle tube
housing located at the lower shock mounting area.
(6) Lower the axle until the spring is free from the
upper mount and isolator (Fig. 10).
(7) Remove the spring from the vehicle.
(8) Remove and inspect the upper and lower
spring isolators.
INSTALLATION
(1) Install the upper isolator.
(2) Install the lower isolator with the isolator loca-
tor nub in the axle pad hole (Fig. 11).
(3) Position the coil spring on the axle spring pad.CAUTION: Ensure the spring is positioned on the
lower isolator with the end of the spring coil
against the isolator spring locator (Fig. 12).
(4) Raise the axle and guide the springs onto the
spring upper mounts and lower shock studs into the
axle brackets.
(5) Install the shock absorbers lower mounting
nuts.
Fig. 10 Front Coil Spring
1 - UPPER ISOLATOR
2 - COIL SPRING
3 - LOWER ISOLATOR
4 - STABILIZER LINK
Fig. 11 Lower Isolator
1 - LOCATING NUB
2 - LOWER ISOLATOR
3 - AXLE SPRING PAD
4 - LOCATING HOLE
Fig. 12 Isolator Spring Locator
1 - COIL SPRING
2 - SPRING LOCATOR
3 - LOWER ISOLATOR
WJFRONT 2 - 13
SPRING (Continued)

REAR
TABLE OF CONTENTS
page page
REAR
DESCRIPTION.........................17
WARNING.............................17
DIAGNOSIS AND TESTING - REAR
SUSPENSION........................18
SPECIFICATIONS
TORQUE CHART......................18
SPECIAL TOOLS
REAR SUSPENSION...................19
LOWER CONTROL ARM
DESCRIPTION.........................19
OPERATION...........................19
REMOVAL.............................19
INSTALLATION.........................19
SHOCK
DESCRIPTION.........................19
OPERATION...........................19
REMOVAL.............................19
INSTALLATION.........................19
SPRING
DESCRIPTION.........................20OPERATION...........................20
REMOVAL.............................20
INSTALLATION.........................20
STABILIZER BAR
DESCRIPTION.........................21
OPERATION...........................21
REMOVAL.............................21
INSTALLATION.........................21
UPPER BALL JOINT
DESCRIPTION - UPPER SUSPENSION ARM,
BUSHINGS, AND BALL JOINT............21
OPERATION - UPPER SUSPENSION ARM,
BUSHINGS, AND BALL JOINT............21
REMOVAL.............................21
INSTALLATION.........................22
UPPER CONTROL ARM
DESCRIPTION.........................22
OPERATION...........................22
REMOVAL.............................22
INSTALLATION.........................23
REAR
DESCRIPTION
The rear suspension (Fig. 1) is comprised of :
²Drive axle
²Shock absorbers
²Coil springs
²Lower suspension arms
²Upper suspension arm
²Stabilizer bar
CAUTION: Suspension components with rubber/ure-
thane bushings should be tightened with the vehi-
cle at normal ride height. It is important to have the
springs supporting the weight of the vehicle when
the fasteners are torqued. This will maintain vehicle
ride comfort and prevent premature bushing wear.
WARNING
WARNING:: Suspension components with rubber
bushings must be tightened with the vehicle at nor-
mal ride height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normalride position, vehicle ride comfort will be affected
and cause premature bushing wear.
Fig. 1 Rear Suspension
1 - SHOCK
2 - UPPER SUSPENSION ARM
3 - COIL SPRING
4 - STABILIZER BAR
5 - LOWER SUSPENSION ARM
WJREAR 2 - 17

DIAGNOSIS AND TESTING - REAR
SUSPENSION
CONDITION POSSIBLE CAUSES CORRECTION
VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Replace wheel bearings.
2. Loose, worn or bent suspension
components.2. Inspect, tighten or replace components
as necessary.
3. Tire pressure. 3. Adjust tire pressure.
VEHICLE PULLS TO ONE
SIDE1. Weak or broken spring. 1. Replace spring.
2. Alignment. 2. Align vehicle to specifications.
3.Tires. 3. Replace tires.
4. Brakes. 4. Repair as necassary.
KNOCKING, RATTLING
OR SQUEAKING1. Worn shock bushings. 1. Replace shock.
2. Loose shock mounting. 2. Tighten to specifications.
3. Shock valve. 3. Replace shock.
4. Loose upper ball joint. 4. Replace ball joint.
5. Loose, worn or bent suspension
components.5. Inspect, tighten or replace components
as necessary.
IMPROPER TRACKING 1. Loose, worn or bent suspension
components.1. Inspect, tighten or replace components
as necessary.
2. Bent axle. 2.Replace axle.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Shock Absorber Upper Nut 108 80 Ð
Shock Absorber Lower Nut 115 85 Ð
Suspension Arm Upper Ball Joint Nut 142 105 Ð
Suspension Arm Upper Frame Bolts 100 74 Ð
Ball Joint Plate Bolts 136 100 Ð
Suspension Arms Lower Axle Bracket Nut 163 120 Ð
Suspension Arms Lower Frame Bracket Nut 156 115 Ð
Stabilizer Bar Retainer Bolts 54 40 Ð
Stabilizer Bar Bar Link Nut 54 40 Ð
Stabilizer Bar Bracket Link Nut 92 68 Ð
2 - 18 REARWJ
REAR (Continued)

SPRING
DESCRIPTION
The coil springs mount up in the wheelhouse which
is part of the unitized body bracket. A rubber dough-
nut isolator is located between the top of the spring
and the body. The bottom of the spring seats on a
axle isolator made of rubber with a steel insert. The
isolators provide road noise isolation
OPERATION
The coil springs control ride quality and maintain
proper ride height.
REMOVAL
(1) Raise and support the vehicle. Position a
hydraulic jack under the axle to support the axle.
(2) Remove the wheel and tire assemblies.
(3) Remove the stabilizer bar link from the stabi-
lizer bar (Fig. 4).
(4) Remove the shock absorber lower bolt from the
axle bracket.
(5) Lower the hydraulic jack and tilt the axle and
remove the coil spring (Fig. 4).
(6) Remove and inspect the upper and lower
spring isolators (Fig. 4).
INSTALLATION
(1) Install the upper isolator.
(2) Install the lower isolator with the isolator loca-
tor nub in the axle pad hole (Fig. 5).
(3) Pull down on the axle and position the coil
spring in the lower isolator.CAUTION: Ensure the spring is positioned on the
lower isolator with the end of the spring coil
against the isolator spring locator (Fig. 6).
(4) Raise the axle with the hydraulic jack.
(5) Install the shock absorber to the axle bracket
and tighten to specification.
(6) Install the stabilizer bar link to the stabilizer
bar.
(7) Install the wheel and tire assemblies.
(8) Remove the supports and lower the vehicle.
(9) Tighten the stabilizer bar links to specification.
Fig. 3 Shock Absorber
1 - SHOCKFig. 4 Coil Spring
1 - COIL SPRING
2 - ISOLATOR
3 - STABILIZER LINK
4 - ISOLATOR
Fig. 5 Isolator Locator Nub
1 - LOWER ISOLATOR
2 - LOCATOR NUB
3 - AXLE SPRING PAD
2 - 20 REARWJ
SHOCK (Continued)

DRIVELINE VIBRATION
Drive Condition Possible Cause Correction
Propeller Shaft Noise 1) Undercoating or other foreign material
on shaft.1) Clean exterior of shaft and wash with
solvent.
2) Loose U-joint clamp screws. 2) Install new clamps and screws and
tighten to proper torque.
3) Loose or bent U-joint yoke or
excessive runout.3) Install new yoke.
4) Incorrect driveline angularity. 4) Measure and correct driveline angles.
5) Rear spring center bolt not in seat. 5) Loosen spring u-bolts and seat center
bolt.
6) Worn U-joint bearings. 6) Install new U-joint.
7) Propeller shaft damaged or out of
balance.7) Installl new propeller shaft.
8) Broken rear spring. 8) Install new rear spring.
9) Excessive runout or unbalanced
condition.9) Re-index propeller shaft, test, and
evaluate.
10) Excessive drive pinion gear shaft
runout.10) Re-index propeller shaft and evaluate.
11) Excessive axle yoke deflection. 11) Inspect and replace yoke if necessary.
12) Excessive transfer case runout. 12) Inspect and repair as necessary.
Universal Joint Noise 1) Loose U-joint clamp screws. 1) Install new clamps and screws and
tighten to proper torque.
2) Lack of lubrication. 2) Replace U-joints as necessary.
BALANCE
NOTE: Removing and re-indexing the propeller
shaft 180É relative to the yoke may eliminate some
vibrations.
If propeller shaft is suspected of being unbalanced,
it can be verified with the following procedure:
(1) Raise the vehicle.
(2) Clean all the foreign material from the propel-
ler shaft and the universal joints.
(3) Inspect the propeller shaft for missing balance
weights, broken welds, and bent areas.If the pro-
peller shaft is bent, it must be replaced.
(4) Inspect the universal joints to ensure that they
are not worn, are properly installed, and are cor-
rectly aligned with the shaft.
(5) Check the universal joint clamp screws torque.
(6) Remove the wheels and tires. Install the wheel
lug nuts to retain the brake drums or rotors.
(7) Mark and number the shaft six inches from the
yoke end at four positions 90É apart.
(8) Run and accelerate the vehicle until vibration
occurs. Note the intensity and speed the vibration
occurred. Stop the engine.(9) Install a screw clamp at position 1 (Fig. 1).
Fig. 1 CLAMP SCREW - POSITION 1
1 - CLAMP
2 - SCREWDRIVER
3 - 2 PROPELLER SHAFTWJ
PROPELLER SHAFT (Continued)

(10) Start the engine and re-check for vibration. If
there is little or no change in vibration, move the
clamp to one of the other three positions. Repeat the
vibration test.
(11) If there is no difference in vibration at the
other positions, the source of the vibration may not
be propeller shaft.
(12) If the vibration decreased, install a second
clamp (Fig. 2) and repeat the test.
(13) If the additional clamp causes an additional
vibration, separate the clamps (1/4 inch above and
below the mark). Repeat the vibration test (Fig. 3).
(14) Increase distance between the clamp screws
and repeat the test until the amount of vibration is
at the lowest level. Bend the slack end of the clamps
so the screws will not loosen.
(15) If the vibration remains unacceptable, apply
the same steps to the front end of the propeller shaft.
(16) Install the wheel and tires. Lower the vehicle.RUNOUT
(1) Remove dirt, rust, paint, and undercoating
from the propeller shaft surface where the dial indi-
cator will contact the shaft.
(2) The dial indicator must be installed perpendic-
ular to the shaft surface.
(3) Measure runout at the center and ends of the
shaft sufficiently far away from weld areas to ensure
that the effects of the weld process will not enter into
the measurements.
(4) Refer to Runout Specifications chart.
(5) If the propeller shaft runout is out of specifica-
tion, remove the propeller shaft, index the shaft 180É,
and re-install the propeller shaft. Measure shaft
runout again.
(6) If the propeller shaft runout is now within
specifications, mark the shaft and yokes for proper
orientation.
(7) If the propeller shaft runout is not within spec-
ifications, verify that the runout of the transmission/
transfer case and axle are within specifications.
Correct as necessary and re-measure propeller shaft
runout.
(8) Replace the propeller shaft if the runout still
exceeds the limits.
RUNOUT SPECIFICATIONS
Front of Shaft 0.020 in. (0.50 mm)
Center of Shaft 0.025 in. (0.63 mm)
Rear of Shaft 0.020 in. (0.50 mm)
note:
Measure front/rear runout approximately 3 inches (76
mm) from the weld seam at each end of the shaft
tube for tube lengths over 30 inches. For tube lengths
under 30 inches, the maximum allowed runout is
0.020 in. (0.50 mm) for the full length of the tube.
STANDARD PROCEDURES
This procedure applies to both the front propeller
shafts and the rear propeller shaft. To obtain the
front (output) angle on the C/V front propeller shaft,
the inclinometer is placed on the machined ring of
the pinion flange. To obtain the propeller shaft angle
measurement on the C/V front propeller shaft, the
inclinometer is placed on the propeller shaft tube.
PROPELLER SHAFT ANGLE
(1) Raise and support the vehicle at the axles as
level as possible. Allow the wheels and propeller
shaft to turn.
(2) Remove any external bearing snap rings from
universal joint if equipped, so the inclinometer base
will sits flat.
Fig. 2 TWO CLAMP SCREWS
Fig. 3 CLAMP SCREWS SEPARATED
1 - ó INCH
WJPROPELLER SHAFT 3 - 3
PROPELLER SHAFT (Continued)