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

LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
LUBRICATION & MAINTENANCE
SPECIFICATIONS - FLUID CAPACITIES.......1
INTERNATIONAL SYMBOLS
DESCRIPTION..........................2
PARTS & LUBRICANT RECOMMENDATION
STANDARD PROCEDURE - PARTS &
LUBRICANT RECOMMENDATIONS.........2
FLUID TYPES
DESCRIPTION
DESCRIPTION - ENGINE COOLANT........2
DESCRIPTION - ENGINE COOLANT........3
ENGINE OIL..........................4
DESCRIPTION - ENGINE OIL.............4
DESCRIPTION........................5
DESCRIPTION - TRANSFER CASE - NV242 . . 5
DESCRIPTION - TRANSFER CASE - NV247 . . 5
DESCRIPTION - AUTOMATIC
TRANSMISSION FLUID..................5
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES............................6OPERATION - AUTOMATIC TRANSMISSION
FLUID...............................6
FLUID FILL/CHECK LOCATIONS
INSPECTION - FLUID FILL/CHECK
LOCATIONS..........................6
MAINTENANCE SCHEDULES
DESCRIPTION..........................6
LIFT POINTS
STANDARD PROCEDURE - HOISTING AND
JACKING RECOMMENDATIONS...........6
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING . . 7
EMERGENCY TOW HOOKS
DESCRIPTION..........................8
TOWING
STANDARD PROCEDURE - TOWING
RECOMMENDATIONS...................8
LUBRICATION &
MAINTENANCE
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
FUEL TANK 20 U.S. Gallons (76
Liters)****
Engine Oil - with Filter -
2.7L Diesel6.5L (6.9 qts.)
Engine Oil - with Filter -
4.0L5.7 L (6.0 qts.)
Engine Oil - with Filter -
4.7L5.7 L (6.0 qts.)
Cooling System - 2.7L
Diesel14.2L (15 qts.)***
Cooling System - 4.0L 14.1 L (15 qts.)***
Cooling System - 4.7L 13.7 L (14.5 qts.)***
AUTOMATIC TRANSMISSION
Service Fill - 42RE 3.8 L (4.0 qts.)
Service Fill - 545RFE 2WD - 5.2 L (11 pts.)
4WD - 6.2 L (13 pts.)
O-haul Fill - 42RE 9.1-9.5 L (19-20 pts.)
DESCRIPTION SPECIFICATION
O-haul Fill - 545RFE 13.33 L (28.0 pts.)
Dry fill capacity Depending on type and size of internal
cooler, length and inside diameter of cooler lines, or use
of an auxiliary cooler, these figures may vary. (Refer to
appropriate 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC/FLUID - STANDARD PROCEDURE).
TRANSFER CASE
NV242 1.35L (2.85 pts.)
NV247 1.6L (3.4 pts.)
FRONT AXLE   0.3 L (1 oz.)
186 FBI (Model 30) 1.18 L (2.5 pts.)*
* With Vari-Lok add 0.07 L (2.5 oz.) of Friction Modifier.
REAR AXLE   0.3 L (1 oz.)
198 RBI (Model 35) 1.66 L (3.5 pts.)*
226 RBA (Model 44) 2.24 L (4.75 pts.)**
* With Trac-lok add 0.07 L (2.5 oz.) of Friction Modifier.
** With Trac-lok or Vari-Lok, add 0.07 L (2.5 oz.) of
Friction Modifier.
*** Includes 0.9L (1.0 qts.) for coolant reservoir.
****Nominal refill capacities are shown. A variation may
be observed from vehicle to vehicle due to
manufacturing tolerance and refill procedure.
WJLUBRICATION & MAINTENANCE 0 - 1

ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for
gasoline engines. The designation of ENERGY CON-
SERVING is located on the label of an engine oil con-
tainer.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the label
of engine oil plastic bottles and the top of engine oil
cans (Fig. 6).
DESCRIPTION
A multi-purpose, hypoid gear lubricant which con-
forms to MIL-L-2105C and API GL 5 quality specifi-
cations should be used. Mopar Hypoid Gear
Lubricant conforms to these specifications.
FRONT AXLE
²Lubricant is SAE 75W-140 SYNTHETIC.
REAR AXLE
²Lubricant is a thermally stable SAE 80W-90
gear lubricant.
²Lubricant for heavy-duty or trailer tow use is
SAE 75W-140 SYNTHETIC.
NOTE: Trac-lokTand Vari-lokTequipped axles
require a friction modifier be added to the lubricant.
DESCRIPTION - TRANSFER CASE - NV242
Recommended lubricant for the NV242 transfer
case is MopartATF+4, type 9602 Automatic Trans-
mission Fluid.
DESCRIPTION - TRANSFER CASE - NV247
MopartTransfer Case Lubricant (P/N 05016796) is
the only lubricant recommended for the NV247
transfer case.
DESCRIPTION - AUTOMATIC TRANSMISSION
FLUID
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
MopartATF +4, type 9602, Automatic Transmis-
sion Fluid is the recommended fluid for
DaimlerChrysler automatic transmissions.
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
MopartATF +4, type 9602, Automatic Transmis-
sion Fluid when new is red in color. The ATF is dyed
red so it can be identified from other fluids used in
the vehicle such as engine oil or antifreeze. The red
color is not permanent and is not an indicator of fluid
condition. As the vehicle is driven, the ATF will begin
to look darker in color and may eventually become
brown.This is normal.ATF+4 also has a unique
odor that may change with age. Consequently, odor
and color cannot be used to indicate the fluid condi-
tion or the need for a fluid change.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various ªspecialº additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and
these additivesmust not be used.The use of trans-
mission ªsealersº should also be avoided, since they
may adversely affect the integrity of transmission
seals.
Fig. 5 Temperature/Engine Oil Viscosity - 4.0L
Fig. 6 API Symbol
WJLUBRICATION & MAINTENANCE 0 - 5
FLUID TYPES (Continued)

DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
²When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
²Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
EMERGENCY TOW HOOKS
DESCRIPTION
WARNING: REMAIN AT A SAFE DISTANCE FROM A
VEHICLE THAT IS BEING TOWED VIA ITS TOW
HOOKS. THE TOW STRAPS/CHAINS COULD BREAK
AND CAUSE SERIOUS INJURY.
Some Jeep vehicles are equipped with front emer-
gency tow hooks (Fig. 9). The tow hooks should be
used forEMERGENCYpurposes only.
CAUTION: DO NOT use emergency tow hooks for
tow truck hook-up or highway towing.
TOWING
STANDARD PROCEDURE - TOWING
RECOMMENDATIONS
A vehicle equipped with SAE approved wheel lift-
type towing equipment can be used to tow WJ vehi-
cles. When towing a 4WD vehicle using a wheel-lift
towing device, use tow dollies under the opposite end
of the vehicle. A vehicle with flatbed device can also
be used to transport a disabled vehicle (Fig. 10).
SAFETY PRECAUTIONS
CAUTION: The following safety precautions must be
observed when towing a vehicle:
²Secure loose and protruding parts.
²Always use a safety chain system that is inde-
pendent of the lifting and towing equipment.
Fig. 8 Jumper Cable Clamp Connections
1 - ENGINE GROUND
2 - NEGATIVE JUMPER CABLE
3 - BATTERY NEGATIVE CABLE
4 - POSITIVE JUMPER CABLE
5 - BATTERY POSITIVE CABLE
6 - BATTERY
7 - TEST INDICATOR
Fig. 9 Emergency Tow Hooks
1 - TOW HOOK
Fig. 10 Tow Vehicles With Approved Equipment
0 - 8 LUBRICATION & MAINTENANCEWJ
JUMP STARTING (Continued)

²Do not allow towing equipment to contact the
disabled vehicle's fuel tank.
²Do not allow anyone under the disabled vehicle
while it is lifted by the towing device.
²Do not allow passengers to ride in a vehicle
being towed.
²Always observe state and local laws regarding
towing regulations.
²Do not tow a vehicle in a manner that could
jeopardize the safety of the operator, pedestrians or
other motorists.
²Do not attach tow chains, T-hooks, or J-hooks to
a bumper, steering linkage, drive shafts or a non-re-
inforced frame hole.
²Do not tow a heavily loaded vehicle. Use a flat-
bed device to transport a loaded vehicle.
TWO-WHEEL-DRIVE VEHICLE TOWING
DaimlerChrysler Corporation recommends that a
vehicle be towed with the rear end lifted, whenever
possible.
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION (AUTO-
MATIC TRANSMISSION) OR A FORWARD DRIVE
GEAR (MANUAL TRANSMISSION).
WARNING: ENSURE VEHICLE IS ON A LEVEL SUR-
FACE OR THE WHEELS ARE BLOCKED TO PRE-
VENT VEHICLE FROM ROLLING.
TWO WHEEL DRIVE TOWING-REAR END LIFTED
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
2WD vehicles can be towed with the front wheels
on the surface for extended distances at speeds not
exceeding 48 km/h (30 mph).
(1) Attach wheel lift device to rear wheels.
(2) Place the transmission in neutral.
(3) Raise vehicle to towing position.
(4) Attach safety chains. Route chains so not to
interfere with tail pipe when vehicle is lifted.
(5) Turn the ignition switch to the OFF position to
unlock the steering wheel.
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
(6) Secure steering wheel in straight ahead posi-
tion with a clamp device designed for towing.
(7) Place transmission in park.
TWO WHEEL DRIVE TOWING-FRONT END LIFTED
CAUTION: Many vehicles are equipped with air
dams, spoilers, and/or ground effect panels. To
avoid component damage, a wheel-lift towing vehi-
cle or a flat-bed hauling vehicle is recommended.
(1) Attach wheel lift device to rear wheels.
(2) Place the transmission in neutral.
(3) Raise the rear of the vehicle off the ground and
install tow dollies under rear wheels.
(4) Attach wheel lift device to front wheels and
raise vehicle to towing position.
(5) Attach the safety chains.
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
(6) Turn the ignition switch to the OFF position to
unlock the steering wheel.
(7) Secure steering wheel in straight ahead posi-
tion with a clamp device designed for towing.
(8) Place transmission in park.
FOUR-WHEEL-DRIVE VEHICLE TOWING
DaimlerChrysler Corporation recommends that a
4WD vehicle be transported on a flat-bed device. A
Wheel-lift device can be used providedthe trailing
wheels are off the ground and positioned in
tow dollies.
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION.
CAUTION: Many vehicles are equipped with air
dams, spoilers, and/or ground effect panels. To
avoid component damage, a wheel-lift towing vehi-
cle or a flat-bed hauling vehicle is recommended.
FOUR WHEEL DRIVE TOWINGÐREAR END LIFTED
WARNING: ENSURE VEHICLE IS ON A LEVEL SUR-
FACE OR THE WHEELS ARE BLOCKED TO PRE-
VENT VEHICLE FROM ROLLING.
(1) Attach wheel lift device to front wheels.
(2) Place the transmission in neutral.
(3) Raise the front of the vehicle off the ground
and install tow dollies under front wheels.
(4) Attach wheel lift device to rear wheels and
raise vehicle to towing position.
(5) Attach safety chains. Route chains so not to
interfere with tail pipe when vehicle is lifted.
WJLUBRICATION & MAINTENANCE 0 - 9
TOWING (Continued)

(6) Turn the ignition switch to the OFF position to
unlock the steering wheel.
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
(7) Secure steering wheel in straight ahead posi-
tion with a clamp device designed for towing.
(8) Place transmission in park.
FOUR WHEEL DRIVE TOWINGÐFRONT END
LIFTED
WARNING: ENSURE VEHICLE IS ON A LEVEL SUR-
FACE OR THE WHEELS ARE BLOCKED TO PRE-
VENT VEHICLE FROM ROLLING.
(1) Attach wheel lift device to rear wheels.(2) Place the transmission in neutral.
(3) Raise the rear of the vehicle off the ground and
install tow dollies under rear wheels.
(4) Attach wheel lift device to front wheels and
raise vehicle to towing position.
(5) Attach the safety chains.
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
(6) Turn the ignition switch to the OFF position to
unlock the steering wheel.
(7) Secure steering wheel in straight ahead posi-
tion with a clamp device designed for towing.
(8) Place transmission in park.
0 - 10 LUBRICATION & MAINTENANCEWJ
TOWING (Continued)

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)

DIFFERENTIAL
Differential side bearing preload and gear backlash
is achieved by selective shims positioned behind the
differential side bearing cones. The proper shim
thickness can be determined using slip-fit Dummy
Bearings D-348 in place of the differential side bear-
ings and a Dial Indicator C-3339. Before proceeding
with the differential bearing preload and gear back-
lash measurements, measure the pinion gear depth
and prepare the pinion for installation. Establishing
proper pinion gear depth is essential to establishing
gear backlash and tooth contact patterns. After the
overall shim thickness to take up differential side
play is measured, the pinion is installed, and the
gear backlash shim thickness is measured. The over-
all shim thickness is the total of the dial indicator
reading and the preload specification added together.
The gear backlash measurement determines the
thickness of the shim used on the ring gear side of
the differential case. Subtract the gear backlash shim
thickness from the total overall shim thickness and
select that amount for the pinion gear side of the dif-
ferential (Fig. 9). Differential shim measurements
are performed with spreader W-129-B removed.
SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove differential side bearings from differ-
ential case.
(2) Install ring gear on differential case and
tighten bolts to specification.
(3) Install dummy side bearings D-348 on differen-
tial case.
(4) Install differential case in the housing.
CAUTION: When installing a Vari-LokTdifferential,
the oil feed tube must point to the bottom of the
housing. If differential is forced in with the oil feed
towards the top, the anti-rotation tabs will be dam-
aged.
(5) Record the thickness of Dummy Shims 8107.
Insert the shims between the dummy bearings and
the differential housing (Fig. 10).
Fig. 9 ADJUSTMENT SHIM LOCATIONS
1 - PINION DEPTH SHIM/OIL SLINGER
2 - DIFFERENTIAL BEARING SHIM
3 - RING GEAR
4 - DIFFERENTIAL BEARING SHIM
5 - COLLAPSIBLE SPACER
Fig. 10 DUMMY SHIM LOCATION
1 - DUMMY SHIM
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
4 - DUMMY BEARINGS
3 - 24 FRONT AXLE - 186FBIWJ
FRONT AXLE - 186FBI (Continued)

(10) Push and hold differential case to pinion gear
side of the housing and zero dial indicator (Fig. 15).
(11) Push and hold differential case to ring gear
side of the housing and record dial indicator reading
(Fig. 16).(12) Add 0.152 mm (0.006 in.) to the zero end play
total. This new total represents the thickness of
shims to compress or preload the new bearings when
the differential is installed.
(13) Rotate dial indicator out of the way on the
pilot stud.
(14) Remove differential case and dummy bearings
from the housing.
(15) Install the pinion gear in the housing. Install
the pinion yoke and establish the correct pinion
rotating torque.
(16) Install differential case and Dummy Bearings
D-348 in the housing.
(17) Install a single dummy shim in the ring gear
side. Install bearing caps and tighten bolts snug.
(18) Seat ring gear side dummy bearing (Fig. 13).
(19) Position the dial indicator plunger on a flat
surface between the ring gear bolt heads (Fig. 14).
(20) Push and hold differential case toward pinion
gear and zero dial indicator (Fig. 17).
Fig. 15 ZERO DIAL INDICATOR
1 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
2 - PILOT STUD
3 - INDICATOR EXTENSION
4 - DIAL INDICATOR FACE
Fig. 16 RECORED DIAL INDICATOR READING
1 - DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
3 - DIFFERENTIAL HOUSING
Fig. 17 ZERO DIAL INDICATOR
1 - DIAL INDICATOR
2 - FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
3 - 26 FRONT AXLE - 186FBIWJ
FRONT AXLE - 186FBI (Continued)

(21) Push and hold differential case to ring gear
side of the housing and record dial indicator reading
(Fig. 18). Add dummy shim thickness to this reading.
This will be the total shim thickness to achieve zero
backlash.
(22) Subtract 0.076 mm (0.003 in.) from the dial
indicator reading to compensate for backlash between
ring and pinion gears. This total is the thickness
shim required to achieve proper backlash.
(23) Subtract the backlash shim thickness from
the total preload shim thickness. The remainder is
the shim thickness required on the pinion side of the
axle housing.
(24) Rotate dial indicator out of the way on pilot
stud.(25) Remove differential case and dummy bearings
from the housing.
(26) Install side bearings and cups on differential
case.
(27) Install spreader W-129-B with Adapter Set
6987 on the housing and spread axle opening enough
to receive differential case.
(28) Place the bearing preload shims in the axle
housing, against the axle tubes.
(29) Install differential case into the housing.
CAUTION: When installing a Vari-LokTdifferential,
the oil feed tube must point to the bottom of the
housing. If differential is forced in with the oil feed
towards the top, the anti-rotation tabs will be dam-
aged.
(30) Remove spreader from the housing.
(31) Rotate the differential case several times to
seat the side bearings.
(32) Position the indicator plunger against a ring
gear tooth (Fig. 19).
Fig. 18 RECORED DIAL INDICATOR READING
1 - DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
Fig. 19 RING GEAR BACKLASH
1 - DIAL INDICATOR
WJFRONT AXLE - 186FBI 3 - 27
FRONT AXLE - 186FBI (Continued)

(33) Push and hold ring gear upward while not
allowing the pinion gear to rotate.
(34) Zero dial indicator face to pointer.
(35) Push and hold ring gear downward while not
allowing the pinion gear to rotate. Dial indicator
reading should be between 0.12 mm (0.005 in.) and
0.20 mm (0.008 in.). If backlash is not within specifi-
cations transfer the necessary amount of shim thick-
ness from one side of the housing to the other (Fig.
20).
(36) Verify differential case and ring gear runout
by measuring ring to pinion gear backlash at eight
locations around the ring gear. Readings should not
vary more than 0.05 mm (0.002 in.). If readings vary
more than specified, the ring gear or the differential
case is defective.
After the proper backlash is achieved, perform
Gear Contact Pattern Analysis procedure.
GEAR CONTACT PATTERN
The ring gear and pinion teeth contact patterns
will show if the pinion depth is correct in the hous-
ing. It will also show if the ring gear backlash has
been adjusted correctly. The backlash can be adjusted
within specifications to achieve desired tooth contact
patterns.
(1) Apply a thin coat of hydrated ferric oxide or
equivalent to the drive and coast side of the ring gear
teeth.
(2) Wrap, twist and hold a shop towel around the
pinion yoke to increase the turning resistance of the
pinion. This will provide a more distinct contact pat-
tern.
(3) With a boxed end wrench on a ring gear bolt,
rotate the differential case one complete revolution inboth directions while a load is being applied from
shop towel.
The areas on the ring gear teeth with the greatest
degree of contact against the pinion teeth will squee-
gee the compound to the areas with the least amount
of contact. Note and compare patterns on the ring
gear teeth to Gear Tooth Contact Patterns chart (Fig.
21)and adjust pinion depth and gear backlash as nec-
essary.
Fig. 20 BACKLASH SHIM ADJUSTMENT
3 - 28 FRONT AXLE - 186FBIWJ
FRONT AXLE - 186FBI (Continued)