JEEP XJ 1995 Service And Repair Manual

The retaining screws and the steering gear
skid plate must be removed before the left
strap can be removed from the sillmember.
(5) Detach the tow hook straps from the sillmem-
ber.
(6) Support the bumper.
(7) Remove the bolts that attach the bumper sup-
port brackets to the right and left sillmembers (Fig.
5).
(8) Remove the support and the bumper from the
vehicle (Fig. 5).
(9) Remove the nuts and bolts that attach the tow
hooks to the bumper support brackets.
(10) Remove the support brackets (Fig. 6), bumper
guards (Fig. 7) and caps (Fig. 8) from the bumper
rail.(11) Remove the license plate bracket (Fig. 9), if
equipped, from the bumper rail.
Fig. 5 Front Bumper Removal/Installation
Fig. 6 Bumper Support Bracket Removal/Installation
Fig. 7 Bumper Guard Removal/Installation
Fig. 8 Bumper End Cap Removal/Installation
Fig. 9 Bumper License Plate Bracket Removal/
Installation
13 - 6 XJÐBUMPERSJ

(12) Remove the fog lamps (Fig. 10) from the
bumper rail.
(13) If necessary, remove the vacuum reservoir(s)
from the bumper rail.
(14) If necessary, remove the sill crossmember re-
inforcement brackets from the sillmembers.
ASSEMBLY/INSTALLATION
(1) If removed, install the sill crossmember rein-
forcement brackets on the sillmembers (Fig. 11).
Tighten bolts to 56 Nzm (41 ft. lbs.) torque.
(2) If equipped, install the bumper support brack-
ets and bumper guards on the bumper rail. Tighten
hardware in the sequence indicated in (Fig. 6).
Tighten the locknuts with 20 Nzm (15 ft. lbs.) torque.
Tighten bolts to 56 Nzm (41 ft. lbs.) torque.
(3) If not equipped with bumper guards, install the
bumper support brackets on the bumper rail. Tighten
bolts to 56 Nzm (41 ft. lbs.) torque.
(4) Install tow hooks. Tighten nuts with 100 Nzm
(74 ft. lbs.) torque.
(5) Install the bumper end caps on the bumper
rail. Tighten nuts with 8 Nzm (72 in. lbs.) torque.(6) Install the license plate bracket on the bumper
rail. Tighten the nuts securely.
(7) Install the fog lamps on the bumper rail.
Tighten the nuts to 20 Nzm (15 ft. lbs.) torque.
(8) If removed, install the vacuum reservoir(s) on
the bumper rail. Tighten the retaining screws and
bolts to 8 Nzm (72 in. lbs.) torque.
(9) Position and support the bumper at the front of
the vehicle.
(10) Attach the bumper support brackets to the
right and left sillmembers and reinforcement brack-
ets. Tighten screws and bolts to 56 Nzm (41 ft. lbs.)
torque.
(11) Install the Torx-head bolts and locknuts that
attach the tow hook straps to the underbody sillmem-
ber. Tighten locknuts with 30 Nzm (22 ft. lbs.) torque.
Install the steering gear skid plate and screws
after the left tow hook strap has been installed.
(12) Connect the fog lamp wire harness connectors.
(13) Connect the vacuum reservoir tube harness
connectors.
(14) Remove the bumper support.
FRONT TOW HOOKS
If a tow hook must be replaced or removed only for
service access, remove the nuts and bolts that attach
it to the bumper support bracket. When installing a
tow hook, tighten nuts with 100 Nzm (74 ft. lbs.)
torque.
If a tow hook/bumper support bracket must be re-
placed, refer to the following removal and installation
procedures.
REMOVAL
If equipped with a brush guard, refer to the Brush
Guard Removal within Group 23, Body Components.
(1) Disconnect the fog lamp wire harness connec-
tors, if equipped.
(2) Disconnect the vacuum reservoir tube harness
connectors.
(3) Support the bumper.
(4) Remove the bolts that attach the bumper sup-
port brackets to the right and left sillmembers.
(5) Remove the locknuts and Torx-head bolts that
attach the tow hook straps to the underbody sillmem-
ber.
The retaining screws and the steering gear
skid plate must be removed before the left
strap can be removed from the sillmember.
(6) Detach the tow hook straps from the sillmem-
ber.
(7) Remove the support and the bumper from the
vehicle.
(8) Remove the nuts and bolts that attach the tow
hooks to the bumper support brackets.
(9) Remove the tow hook from the bumper support
bracket.
Fig. 10 Fog Lamp
Fig. 11 Reinforcement Brackets
JXJÐBUMPERS 13 - 7

(10) Remove the support bracket from the bumper
rail.
INSTALLATION
(1) Install the bumper guard and bumper support
bracket on the bumper rail. Tighten the retaining
hardware in the sequence indicated in Figure 7.
Tighten locknuts to 20 Nzm (15 ft. lbs.) torque.
Tighten bolts to 56 Nzm (41 ft. lbs.) torque.
(2) If not equipped with bumper guards, install the
bumper support bracket on the bumper rail. Tighten
bolts to 56 Nzm (41 ft. lbs.) torque.
(3) Position the tow hook at the support bracket.
Install the bolts and nuts that attach tow hook to the
bumper support bracket. Tighten nuts to 100 Nzm (74
ft. lbs.) torque.
(4) Position and support the bumper at the front of
the vehicle.
(5) Attach the bumper support brackets to the
right and left sillmembers and reinforcement brack-
ets. Tighten screws and bolts to 56 Nzm (41 ft. lbs.)
torque.
(6) Install the Torx-head bolts and locknuts that
attach the tow hook straps to the underbody sillmem-
ber. Tighten locknuts to 30 Nzm (22 ft. lbs.) torque.
Install the steering gear skid plate and screws
after the left tow hook strap has been installed.
(7) Connect the fog lamp wire harness connectors.
Connect the vacuum reservoir tube harness connec-
tors.
(8) Remove the bumper support.
REAR BUMPER
REMOVAL
(1) For vehicles equipped with a trailer hitch, re-
move the hitch before removing the bumper. If neces-
sary, refer to the removal procedure within Group 23,
Body Components.
(2) Raise and support the rear of the vehicle.
(3) Support the bumper.
(4) Remove the bolts that attach the bumper sup-
port brackets to the sill crossmember (Fig. 12).
(5) Remove the support and the rear bumper from
the vehicle.
(6) Remove the bumper support brackets and
splash shield the bumper, if necessary (Fig. 13).
(7) Remove the bumper end caps (Fig. 14) and
bumper guards from the bumper (Fig. 15), if neces-
sary.
INSTALLATION
(1) As applicable, install the splash shield and
bumper support brackets, the bumper end caps and
the bumper guards.
(2) Tighten the bumper support bolts to 56 Nzm (41
ft. lbs.).(3) Tighten the nuts in the sequence depicted in
Figure 14. Tighten the bumper end cap plate bolt
Fig. 12 Rear Bumper Removal/InstallationÐXJ
Vehicles
Fig. 13 Bumper Bracket & Splash Shield Removal/
InstallationÐXJ Vehicles
Fig. 14 Bumper End Cap Removal/InstallationÐXJ
Vehicles
13 - 8 XJÐBUMPERSJ

nuts to 22 Nzm (16 ft. lbs.) torque. Tighten the lower
bolt nuts to 8 Nzm (6 ft. lbs.) torque.
(4) If applicable, tighten the bumper guard bolts/
nuts to 56 Nzm (41 ft. lbs.).
(5) Position and support the bumper with the
bracket holes aligned with the sill crossmember
holes. Install the bracket-to-crossmember bolts.
Tighten the bolts to 42 Nzm (31 ft. lbs.) torque.
(6) If removed, install the trailer hitch. If neces-
sary, refer to the installation procedure within Group
23, Body Components.
REAR TOW HOOK
REMOVAL
(1) Remove the bolts that attach tow hook bracket
to the frame rail and reinforcement bracket (Fig. 16).
The reinforcement bracket is held on the
frame rail with two blind rivets.
(2) Remove the bracket and tow hook from frame
rail.
INSTALLATION
(1) Position bracket and tow hook on the frame
rail.
(2) Install bolts that attach tow hook bracket to
frame rail and reinforcement bracket. Tighten bolts
to 75 Nzm (55 ft. lbs.) torque.
Fig. 15 Bumper Guard Removal/InstallationÐXJ
VehiclesFig. 16 Rear Tow HookÐXJ Vehicles
JXJÐBUMPERS 13 - 9

FRAME
INDEX
page page
Frame Dimensions........................ 13
Frame Repairs........................... 13
Frame Straightening....................... 13
Fuel Tank Skid Plate....................... 15
General Information....................... 10Generator Splash Shield.................... 13
Safety Precautions and Warnings............. 10
Tow Hooks.............................. 13
Transfer Case Skid Plate.................... 15
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND-
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT.
BEFORE PROCEEDING WITH FRAME REPAIR IN-
VOLVING GRINDING OR WELDING, VERIFY THAT
VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN
CONTACT WITH REPAIR AREA, PERSONAL INJURY
CAN RESULT.
DO NOT ALLOW OPEN FLAME TO CONTACT
PLASTIC BODY PANELS. FIRE OR EXPLOSION CAN
RESULT.
WHEN WELDED FRAME COMPONENTS ARE RE-
PLACED, 100% PENETRATION WELD MUST BE
ACHIEVED DURING INSTALLATION. IF NOT, DAN-
GEROUS OPERATING CONDITIONS CAN RESULT.
STAND CLEAR OF CABLES OR CHAINS ON
PULLING EQUIPMENT DURING FRAME STRAIGHT-
ENING OPERATIONS, PERSONAL INJURY CAN RE-
SULT.
DO NOT VENTURE UNDER A HOISTED VEHICLE
THAT IS NOT SUPPORTED ON SAFETY STANDS,
PERSONAL INJURY CAN RESULT.
CAUTION: Do not reuse damaged fasteners, quality
of repair would be suspect.
Do not drill holes in top or bottom frame rail
flanges, frame rail failure can result.
Do Not use softer than Grade 3 bolts to replace
production fasteners, loosening or failure can re-
sult.When using heat to straighten frame components
do not exceed 566ÉC (1050ÉF), metal fatigue can re-
sult.
Welding the joints around riveted cross members
and frame side rails can weaken frame
GENERAL INFORMATION
The Jeep YJ (Fig. 1) frame is the structural center
of the vehicle. In addition to supporting the body and
payload, the frame provides a station for the engine.
The vehicle body is attached to the frame with hold-
downs (Fig. 2 and 3).
Fig. 1 JeepÐYJ
13 - 10 YJÐFRAMEJ

Fig. 2 YJ Body & Frame
JYJÐFRAME 13 - 11

Fig. 3 Body HoldDownsÐYJ Vehicles
13 - 12 YJÐFRAMEJ

The frame is constructed of high-strength channel
steel siderails and crossmembers. The crossmembers
join the siderails and retain them in alignment in re-
lation to each other. This provides resistance to
frame twists and strains.
FRAME STRAIGHTENING
When necessary, a conventional frame that is bent
or twisted can be straightened by application of heat.
The temperature must not exceed 566ÉC (1050ÉF).
The use of a specially designed heat crayon can de-
termine the desired temperature. Excessive heat will
decrease the strength of the metal and result in a
weakened frame.
Welding the joints around riveted cross members
and frame side rails is not recommended.
A straightening repair process should be limited to
frame members that are not severely damaged.
FRAME REPAIRS
DRILLING HOLES
Do not drill holes in frame side rail top and bottom
flanges, metal fatigue can result causing frame fail-
ure. Holes drilled in the side of the frame rail must
be at least 38 mm (1.5 in.) from the top and bottom
flanges.
Additional drill holes should be located away from
existing holes.
WELDING
Use MIG, TIG or arc welding equipment to repair
welded frame components.
Frame components that have been damaged should
be inspected for cracks before returning the vehicle
to use. If cracks are found in accessible frame com-
ponents perform the following procedures.
(1) Drill a hole at each end of the crack with a 3
mm (O.125 in.) diameter drill bit.
(2) Using a suitable die grinder with 3 inch cut off
wheel, V-groove the crack to allow 100% weld pene-
tration.
(3) Weld the crack.
(4) If necessary when a side rail is repaired, grind
the weld smooth and install a reinforcement channel
(Fig. 4) over the repaired area.
If a reinforcement channel is required, the
top and bottom flanges should be 0.250 inches
narrower than the side rail flanges. Weld only
in the areas indicated (Fig. 4).
FRAME FASTENERS
Bolts, nuts and rivets can be used to repair frames
or to install a reinforcement section on the frame.
Bolts can be used in place of rivets. When replacing
rivets with bolts, install the next larger size diameter
bolt to assure proper fit. If necessary, drill the hole
out just enough to receive the bolt.Conical-type washers are preferred over the split-
ring type lock washers. Normally, grade-5 bolts are
adequate for frame repair.Grade-3 bolts or softer
should not be used.Tightening bolts/nuts with the
correct torque, refer to the Introduction Group at the
front of this manual for tightening information.
FRAME DIMENSIONS
Frame dimensions are listed in millimeter scale.
All dimensions are from center to center of Principal
Locating Point (PLP), or from center to center of PLP
and fastener location (Fig. 5).
TOW HOOKS
REMOVAL
(1) Remove the two bolts that attach the tow hook
to the bumper rail and to the frame rail.
(2) Remove the tow hook.
INSTALLATION
(1) Position the tow hook on the bumper rail and
frame rail.
(2) Install the attaching bolts. Tighten the bolts to
102 Nzm (75 ft. lbs.) torque.
GENERATOR SPLASH SHIELD
REMOVAL
(1) Remove the shield retaining nut and washer
(Fig. 6) from the engine oil pan stud (2.5L engines
only).
(2) Pry the serrated retainers from the frame rail
holes at each side of the vehicle.
(3) Pry the serrated retainers from the fan shroud
holes (Fig. 6).
(4) Remove the shield from the vehicle.
Fig. 4 Frame Reinforcement
JYJÐFRAME 13 - 13

Fig. 5 Frame Alignment DimensionsÐYJ Vehicles
13 - 14 YJÐFRAMEJ

INSTALLATION
(1) Position the generator splash shield at the fan
shroud and frame rails.
(2) Force the serrated retainers into the fan shroud
holes.
(3) Force the serrated retainers into the frame rail
holes at each side of the vehicle.
TRANSFER CASE SKID PLATE
REMOVAL
(1) Raise and support the transmission.
(2) Remove the nuts that attach the transmission sup-
port cushion and torque bracket to the skid plate (Fig. 7).
(3) Separate the transmission support cushion
from the skid plate.(4) Remove the nuts and bolts that attach the skid
plate to the frame.
(5) Remove the skid plate from the vehicle.
INSTALLATION
(1) Position the skid plate at the frame and trans-
mission support cushion.
(2) Attach the skid plate to the frame.
(3) Install the nuts that attach the transmission
support cushion and torque bracket to the skid plate.
Tighten the nuts to 56 Nzm (41 ft. lbs.) torque.
(4) Remove the support and lower the transmission.
FUEL TANK SKID PLATE
REMOVAL
(1) Position a support under the fuel tank skid plate.
(2) Remove the nuts that attach the skid plate to
the straps and to the crossmembers (Fig. 8).
(3) Separate the fuel tank strap from the skid
plate.
(4) Support the fuel tank and remove the skid
plate and the pad from the vehicle.
INSTALLATION
(1) Attach the skid plate to the fuel tank strap.
(2) Position and support the pad and skid plate un-
der the fuel tank.
(3) Install the nuts to attach the skid plate to the
straps and to the frame crossmembers. Tighten the
fuel tank strap nuts to 5 Nzm (40 in. lbs.) torque.
Tighten the skid plate-to-crossmember nuts with 16
Nzm (138 in. lbs.) torque.
(4) Remove the support from under the skid plate.
Fig. 6 Generator Splash Shield
Fig. 7 Transfer Case Skid Plate
Fig. 8 Fuel Tank Skid Plate
JYJÐFRAME 13 - 15