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

GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
3Driveline
5Brakes
7Cooling
8AAudio
8BChime/Buzzer
8EElectronic Control Modules
8FEngine Systems
8GHeated Systems
8HHorn
8IIgnition Control
8JInstrument Cluster
8LLamps
8MMessage Systems
8NPower Systems
8ORestraints
8PSpeed Control
8QVehicle Theft Security
8RWipers/Washers
8WWiring
9Engine
11Exhaust System
13Frame & Bumpers
14Fuel System
19Steering
21Transaxle
22Tires/Wheels
23Body
24Heating & Air Conditioning
25Emissions Control
Service Manual Comment Forms (Rear of Manual)

DESCRIPTION - ENGINE OIL - DIESEL
ENGINES
Use only Diesel Engine Oil meeting standardMIL-
2104Cor API ClassificationCD or higherorCCML
D4, D5.
SAE VISCOSITY GRADE
CAUTION: Low viscosity oils must have the proper
API quality or the CCMC G5 designation.
To assure of properly formulated engine oils, it is
recommended that SAE Grade 10W-40 engine oils
that meet Chrysler material standard MS-6395, be
used. European Grade 10W-40 oils are also accept-
able.
Oils of the SAE 5W-40 or 8W-80 grade number are
preferred when minimum temperatures consistently
fall below -12ÉC.
OPERATION - AUTOMATIC TRANSMISSION
FLUID
The automatic transmission fluid is selected based
upon several qualities. The fluid must provide a high
level of protection for the internal components by
providing a lubricating film between adjacent metal
components. The fluid must also be thermally stable
so that it can maintain a consistent viscosity through
a large temperature range. If the viscosity stays con-
stant through the temperature range of operation,
transmission operation and shift feel will remain con-
sistent. Transmission fluid must also be a good con-
ductor of heat. The fluid must absorb heat from the
internal transmission components and transfer that
heat to the transmission case.
FLUID FILL/CHECK
LOCATIONS
INSPECTION - FLUID FILL/CHECK LOCATIONS
The fluid fill/check locations and lubrication points
are located in each applicable group.
MAINTENANCE SCHEDULES
DESCRIPTION
9Maintenance Schedule Information not included in
this section, is located in the appropriate Owner's
Manual.9
LIFT POINTS
STANDARD PROCEDURE - HOISTING AND
JACKING RECOMMENDATIONS
FLOOR JACK
When properly positioned, a floor jack can be used
to lift a WJ vehicle (Fig. 7). Support the vehicle in
the raised position with jack stands at the front and
rear ends of the frame rails.
CAUTION: Do not attempt to lift a vehicle with a
floor jack positioned under:
²An axle tube.
²Aluminum differential.
²A body side sill.
²A steering linkage component.
²A drive shaft.
²The engine or transmission oil pan.
²The fuel tank.
²A front suspension arm.
HOIST
A vehicle can be lifted with:
²A single-post, frame-contact hoist.
²A twin-post, chassis hoist.
²A ramp-type, drive-on hoist.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly
(Fig. 7).
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.
0 - 6 LUBRICATION & MAINTENANCEWJ
FLUID TYPES (Continued)

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

CONDITION POSSIBLE CAUSES CORRECTION
VEHICLE PULLS TO ONE
SIDE DURING BRAKING1. Uneven tire pressure. 1. Adjust tire pressure.
2. Worn brake components. 2. Repair brakes as necessary.
3. Air in brake line. 3. Repair as necessary.
VEHICLE LEADS OR
DRIFTS FROM STRAIGHT
AHEAD DIRECTION ON
UNCROWNED ROAD1. Radial tire lead. 1. Cross front tires.
2. Brakes dragging. 2. Repair brake as necessary.
3. Weak or broken spring. 3. Replace spring.
4. Uneven tire pressure. 4. Adjust tire pressure.
5. Wheel Alignment. 5. Align vehicle.
6. Loose or worn steering or
suspension components.6. Repair as necessary.
7. Cross caster out of spec. 7. Align vehicle.
KNOCKING, RATTLING
OR SQUEAKING1. Worn shock bushings. 1. Replace shock.
2. Loose, worn or bent steering/
suspension components.2. Inspect, tighten or replace components
as necessary.
3. Shock valve. 3. Replace shock.
IMPROPER TRACKING 1. Loose, worn or bent track bar. 1. Inspect, tighten or replace component as
necessary.
2. Loose, worn or bent steering/
suspension components.2. Inspect, tighten or replace components
as necessary.
2 - 2 SUSPENSIONWJ
SUSPENSION (Continued)

WHEEL ALIGNMENT
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT
DESCRIPTION..........................3
OPERATION............................3
STANDARD PROCEDURE
STANDARD PROCEDURE - CAMBER.......3STANDARD PROCEDURE - CASTER.......4
STANDARD PROCEDURE - TOE POSITION . . 4
SPECIFICATIONS
ALIGNMENT..........................5
WHEEL ALIGNMENT
DESCRIPTION
Wheel alignment involves the correct positioning of
the wheels in relation to the vehicle. The positioning
is accomplished through suspension and steering
linkage adjustments. An alignment is considered
essential for efficient steering, good directional stabil-
ity and to minimize tire wear. The most important
measurements of an alignment are caster, camber
and toe position (Fig. 1).
CAUTION: Never attempt to modify suspension or
steering components by heating or bending.
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.
NOTE: Periodic lubrication of the front suspension/
steering system components may be required. Rub-
ber bushings must never be lubricated, Refer to
Lubrication And Maintenance for the recommended
maintenance schedule.
OPERATION
²CASTERis the forward or rearward tilt of the
steering knuckle from vertical. Tilting the top of the
knuckle rearward provides positive caster. Tilting the
top of the knuckle forward provides negative caster.
Caster is a directional stability angle. This angle
enables the front wheels to return to a straight
ahead position after turns (Fig. 1).
²CAMBERis the inward or outward tilt of the
wheel relative to the center of the vehicle. Tilting the
top of the wheel inward provides negative camber.
Tilting the top of the wheel outward provides positive
camber. Incorrect camber will cause wear on theinside or outside edge of the tire. The angle is not
adjustable, damaged component(s) must be replaced
to correct the camber angle (Fig. 1).
²WHEEL TOE POSITIONis the difference
between the leading inside edges and trailing inside
edges of the front tires. Incorrect wheel toe position
is the most common cause of unstable steering and
uneven tire wear. The wheel toe position is thefinal
front wheel alignment adjustment (Fig. 1).
²STEERING AXIS INCLINATION ANGLEis
measured in degrees and is the angle that the steer-
ing knuckles are tilted. The inclination angle has a
fixed relationship with the camber angle. It will not
change except when a spindle or ball stud is dam-
aged or bent. The angle is not adjustable, damaged
component(s) must be replaced to correct the steering
axis inclination angle.
²THRUST ANGLEis the angle of the rear axle
relative to the centerline of the vehicle. Incorrect
thrust angle can cause off-center steering and exces-
sive tire wear. This angle is not adjustable, damaged
component(s) must be replaced to correct the thrust
angle (Fig. 1).
STANDARD PROCEDURE
STANDARD PROCEDURE - CAMBER
Before each alignment reading the vehicle should
be jounced (rear first, then front). Grasp each
bumper at the center and jounce the vehicle up and
down three times. Always release the bumper in the
down position.
To obtain an accurate alignment, a 4 wheel align-
ment machine must be used and the equipment cali-
bration verified.
The wheel camber angle is preset. This angle is not
adjustable and cannot be altered.
WJWHEEL ALIGNMENT 2 - 3

NOTE: Make sure the toe setting does not change
during clamp tightening.
(6) Verify alignment specifications, then turn the
engine off.
STEERING WHEEL CENTERING
NOTE: The steering wheel can be centered without
affecting the toe position.
(1) Loosen the drag link adjustment sleeve clamp
bolts.
(2) Turn the adjustment sleeve to center the
wheel.
(3) Position the clamp bolts as shown (Fig. 2)for
proper clearance.
(4) Tighten the clamp bolts to 68 N´m (50 ft. lbs.).
(5) Road test the vehicle to verify the wheel is cen-
tered.
SPECIFICATIONS
ALIGNMENT
NOTE: Specifications are in degrees.
FRONT WHEELS - STANDARD SUSPENSION
SPECIFICATIONS
DESCRIPTION SPECIFICATION
PREFERRED CASTER
+ 6.75ÉCAMBER
20.37ÉTOTAL
TOE-IN
+ 0.20É
RANGE + 6.0É to
+ 7.5É20.75É
to + 0.5É+ .14É to
+ .26É
MAX RT/LT
DIFFERENCE0.5É 0.5É 0.5É
FRONT WHEELS - UP-COUNTRY SUSPENSION
SPECIFICATIONS
DESCRIPTION SPECIFICATION
PREFERRED CASTER
+ 6.5ÉCAMBER
20.37ÉTOTAL
TOE-IN
+ 0.20É
RANGE + 5.7É to
+ 7.2É20.75É
to+0É+ 0.0É to
+ .36É
MAX RT/LT
DIFFERENCE0.5É 0.5É 0.06É
REAR AXLE
SPECIFICATIONS
DESCRIPTION SPECIFICATION
PREFERRED CAMBER
±.37ÉTHRUST
ANGLE
0ÉTOTAL
TOE-IN
+.37É
RANGE 0É to
±.75É  0.25É 0É to
+.70É
Fig. 2 Steering Linkage
1 - DRAG LINK ADJUSTMENT SLEEVE
2 - TIE ROD ADJUSTMENT SLEEVE
WJWHEEL ALIGNMENT 2 - 5
WHEEL ALIGNMENT (Continued)

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

SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Shock Absorber Upper Nut 35 26 Ð
Shock Absorber Lower Nut 28 Ð 250
Suspension Arm Upper Axle Bracket Nut 61 45 Ð
Suspension Arm Upper Frame Bracket Bolt 61 45 Ð
Suspension Arm Lower Axle Bracket Nut 163 120 Ð
Suspension Arm Lower Frame Bracket Bolt 156 115 Ð
Stabilizer Bar Retainer Bolts 92 68 Ð
Stabilizer Bar Link Upper Nut 106 78 Ð
Stabilizer Bar Link Lower Nut 106 78 Ð
Track Bar Frame Bracket Nut 108 80 Ð
Track Bar Axle Bracket Bolt 100 74 Ð
Hub Bearing Knuckle Bolts 102 75 Ð
Fig. 1 Front
1 - SHOCK
2 - COIL SPRING
3 - UPPER SUSPENSION ARM
4 - STABILIZER BAR
5 - LOWER SUSPENSION ARM
6 - TRACK BAR
WJFRONT 2 - 7
FRONT (Continued)

SPECIAL TOOLS
FRONT SUSPENSION
Remover/Installer Suspension Bushing 7932
Spacer 8279
Nut, Long 7603
Bolt, Special 7604
Remover C-4150A
Remover/Installer 6289
Reciever 6761
Installer 6752
2 - 8 FRONTWJ
FRONT (Continued)

BUSHINGS
REMOVAL
(1) Remove the upper suspension arm from axle.
(2) Position Spacer 8279 over the axle bushing on
a 4x2 vehicle and right side on a 4x4 vehicle.
(3) Place Receiver 7932-1 over flanged end of the
bushing. (Fig. 2).
(4) Place small end of Remover/Install 7932-2
against other side of the bushing.
(5) Install bolt 7604 through remover, bushing and
receiver.
(6) Install Long Nut 7603 and tighten nut too pull
bushing out of the axle bracket.
(7) Remove nut, bolt, receiver, remover and bush-
ing.
NOTE: On 4x2 vehicle and right side of 4x4 vehicle,
leave Spacer 8279 in position for bushing installa-
tion.
INSTALLATION
(1) Place Receiver 7932-1on the other side of the
axle bracket.
(2) Position new bushing up to the axle bracket.,
and large end of Remover/Install 7932-2 against the
bushing (Fig. 3).
(3) Install bolt 7604 through receiver, bushing and
installer.
(4) Install Long Nut 7603 and tighten nut to draw
the bushing into the axle bracket.(5) Remove tools and install the upper suspension
arm.
HUB / BEARING
DESCRIPTION
The bearing used on the front hub of this vehicle is
the combined hub and bearing unit type assembly.
This unit assembly combines the front wheel mount-
ing hub (flange) and the front wheel bearing into a
one piece unit. The wheel mounting studs are the
only replaceable component of the hub/bearing
assembly.
OPERATION
The hub/bearing assembly is mounted to the steer-
ing knuckle and is retained by three mounting bolts
accessible from the back of the steering knuckle. The
hub/bearing unit is not serviceable and must be
replaced as an assembly if the bearing or the hub is
determined to be defective.
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the brake caliper, caliper anchor, rotor
and ABS wheel speed sensor,(Refer to 5 - BRAKES/
ELECTRICAL/FRONT WHEEL SPEED SENSOR -
REMOVAL).
(4) Remove the cotter pin, nut retainer and axle
hub nut.
(5) Remove the hub bearing mounting bolts from
the back of the steering knuckle. Remove hub bear-
Fig. 2 Bushing Removal
1 - RECEIVER
2 - AXLE BRACKET
3 - BOLT
4 - REMOVER/INSTALLER
5 - LONG NUT
Fig. 3 Bushing Installation
1 - REMOVER/INSTALLER
2 - AXLE BRACKET
3 - BOLT
4 - RECEIVER
5 - LONG NUT
WJFRONT 2 - 9