tow JEEP XJ 1995 Service And User Guide

4WD YJ VEHICLES
(1) Raise the rear of the vehicle off the ground and
install tow dollies under rear wheels.
CAUTION: Use tow chains with T-hooks for con-
necting to the disabled vehicle's frame rails. Never
use J-hooks.
(2) Attach the T-hooks to the slots in the front end
of each frame rail (Fig. 7).
(3) Position each safety chain over the top of each
front spring and inboard of each front spring shackle.
(4) Double wrap each chain.
(5) Position the sling crossbar under the front
bumper.
(6) Turn the ignition switch to the OFF position to
unlock the steering wheel.
(7) Shift the transfer case to NEUTRAL.
TOWING WHEN KEYS ARE NOT AVAILABLE
When the vehicle is locked and keys are not avail-
able, use a flat bed hauler. A Wheel-lift or Sling-type
device can be used provided all the wheels are lifted
off the ground using tow dollies (Fig. 8).
EMERGENCY TOW HOOKS
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 and
rear emergency 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.
FLAT TOWING (4 TIRES/WHEELS ON
SURFACE)
Tow a vehicle in this manner only when all four
wheels will freely rotate. Prepare the vehicle accord-
ing to the following procedures.
2WD VEHICLES
(1) Mark the drive shaft and the axle drive pinion
gear shaft yoke for installation alignment reference.
(2) Remove the drive shaft. Install a protective cov-
ering over the drive shaft U-joints to retain them as-
sembled and protected.
Fig. 7 Sling-Type, Front-End Towing (YJ Vehicles)
Fig. 8 Sling-Type, Front-End Towing With Rear
Wheels On A Tow Dolly
Fig. 9 Emergency Front Tow HooksÐXJ & YJ
Vehicles
JLUBRICATION AND MAINTENANCE 0 - 13

(3) Cover the open end of the transmission exten-
sion housing.
4WD VEHICLESÐXJ
(1) Shift transfer case lever to NEUTRAL.
(2) Place ignition switch in the unlocked position.
4WD VEHICLESÐYJ
CAUTION: Follow these steps to be certain that the
transfer case is fully in N (NEUTRAL) and that the
axle is completely disengaged before flat towing to
prevent damage to internal parts.
(1) Shift transfer case into 2H and check that the
4WD light goes out.
(2) Start engine and drive the vehicle 3 mm (10 ft.)
rearward and then 3 mm (10 ft.) forward to make
sure the axle is disengaged.(3) Shift transmission to Neutral.
(4) Turn off engine with the ignition key in the un-
locked OFF position.
(5) Shift transfer case lever from 2H to N (NEU-
TRAL) position.
(6) Shift manual transmission into gear or auto-
matic transmission into P (PARK).
WARNING: WITH THE TRANSFER CASE IN NEU-
TRAL POSITION, THE VEHICLE COULD ROLL UN-
EXPECTEDLY. THE PARKING BRAKE SHOULD
ALWAYS BE APPLIED BEFORE THE TOW BAR IS
ATTACHED.
(7) Attach vehicle to the tow vehicle with tow bar.
CAUTION: Do not use a bumper mounted clamp-on
tow bar, damage to bumper face bar may occur.
0 - 14 LUBRICATION AND MAINTENANCEJ

line. You may encounter fuels containing 3 percent or
more methanol along with other alcohols called cosol-
vents.
Problems that are the result of using methanol/gas-
oline blends are not the responsibility of Chrysler
Corporation. They may not be covered by the vehicle
warranty.
MTBE/ETBE
Gasoline and MTBE (Methyl Tertiary Butyl Ether)
blends are a mixture of unleaded gasoline and up to
15 percent MTBE. Gasoline and ETBE (Ethyl Ter-
tiary Butyl Ether) are blends of gasoline and up to
17 percent ETBE. Gasoline blended with MTBE or
ETBE may be used.
CLEAN AIR GASOLINE
Many gasolines are now being blended that con-
tribute to cleaner air, especially in those areas of the
country where air pollution levels are high. These
new blends provide a cleaner burning fuel and some
are referred to asReformulated Gasoline.
In areas of the country where carbon monoxide lev-
els are high, gasolines are being treated with oxygen-
ated materials such as MTBE, ETBE and ethanol.
Chrysler Corporation supports these efforts toward
cleaner air and recommends the use of these gaso-
lines as they become available.
IGNITION CABLES, DISTRIBUTOR CAP AND
ROTOR
Inspect and test ignition cables, distributor cap and
rotor when the spark plugs are replaced. Oil and
grime should be cleaned from the ignition cables and
distributor cap to avoid possible spark plug fouling.
Mopar Foamy Engine Degreaser or equivalent is rec-
ommended for cleaning the engine compartment. For
proper service and diagnostic procedures refer to
Group 8D, Ignition System.
IGNITION TIMING
The ignition timing for 2.5L and 4.0L engines is
not adjustable. Refer to the specifications listed on
the engine Emission Control Information Label. Re-
fer to Group 25, Emission Control Systems for addi-
tional information.
SPARK PLUGS
Ignition spark plugs should be replaced at the
mileage interval described in the Lubrication and
Maintenance Schedules. Refer to the General Infor-
mation section of this group. For proper service pro-
cedures refer to Group 8D, Ignition Systems.
BATTERY
WARNING: WEAR SAFETY GLASSES, RUBBER
GLOVES AND PROTECTIVE CLOTHING WHEN HAN-DLING/SERVICING A BATTERY. THE BATTERY
ELECTROLYTE CONTAINS SULFURIC ACID AND
WILL CAUSE HARM IF IT CONTACTS SKIN, EYES
OR CLOTHING. IT WILL ALSO DAMAGE PAINTED
(AS WELL AS UN-PAINTED) SURFACES OF A VEHI-
CLE. IF SULFURIC ACID CONTACTS ANY OF
THESE, FLUSH IMMEDIATELY WITH LARGE
AMOUNTS OF WATER. IF SULFURIC ACID CON-
TACTS SKIN OR EYES, GET IMMEDIATE MEDICAL
ATTENTION. DO NOT SMOKE IN THE VICINITY OF A
BATTERY. KEEP OPEN FLAMES AND SPARKS
AWAY FROM BATTERY FILLER CAPS BECAUSE
EXPLOSIVE GAS IS ALWAYS PRESENT.
Inspect battery tray, hold down and terminal con-
nections when other under hood service is performed.
For proper diagnostic procedures refer to Group 8A,
Battery/Starting/Charging System Diagnostics. For
service and cleaning procedures refer to Group 8B,
Battery/Starter Service.
Care should be taken when disposing a bat-
tery after removal from a vehicle. Lead-acid
batteries are highly poisonous and, when indis-
criminately disposed, could create a problem
for the environment. Contact the applicable lo-
cal city or county government agency to deter-
mine where automobile (lead-acid) batteries
can be properly disposed in the local area.
RUBBER AND PLASTIC COMPONENT INSPECTION
CAUTION: Plastic hoses or wire harness covers will
melt or deform when exposed to heat from exhaust
system or engine manifolds.
Position plastic or rubber components away from
moving parts in engine compartment or under vehi-
cle, or damage will result.
Do not allow rubber engine mounts or other com-
ponents to become oil contaminated, repair cause
of oil contamination and clean area.
All rubber and plastic components should be in-
spected when engine compartment or under vehicle
service is performed. When evidence of deterioration
exists, replacement is required. To reduce deteriora-
tion of rubber components, Chrysler Corporation rec-
ommends Mopar Foamy Engine Degreaser or
equivalent be used to clean engine compartment of
oil and road grime.
EMISSION CONTROL SYSTEM
Inspect all emission control components and hoses
when other under hood service is performed. Refer to
emission system Vacuum Hose Label located on the
inside of the hood in the engine compartment and
Group 25, Emission Control Systems for proper ser-
vice procedures.
0 - 20 LUBRICATION AND MAINTENANCEJ

SPECIAL ADDITIVES
The addition of any special-type fluid to a Jeep au-
tomatic transmission is not recommended. The only
exception is the addition of black-light detection dye
to aid in detecting the source of ATF leaks. The use
of transmission sealing additives should also be
avoided.
Black-light detection dye is factory-installed
in automatic transmissions and, unless the ATF
has been drained and re-placed, it is not neces-
sary to add dye.
FLUID AND FILTER CHANGE
The automatic transmission fluid and filter should
be changed at the intervals described in the Mainte-
nance Schedules section of this Group. Refer to
Group 21, Transmission for proper service proce-
dures.
TRANSFER CASE (4WD VEHICLES)
The transfer case should be inspected for fluid
leaks and proper fluid level when other under vehicle
service is performed.
FLUID LEVEL
The transfer case fill hole plug is located at the
rear of the housing (Fig. 5).
Determine the transfer case fluid (ATF) level ac-
cording to the following procedure.(1) Raise and support the vehicle.
(2) Remove the fill hole plug from the transfer case
(Fig. 5). The fluid (ATF) level should be at the bottom
edge of the fill hole. The level can be slightly below
the bottom edge of the fill hole if the fluid is cold.
(3) If the level is not acceptable, raise the fluid
level to the bottom edge of the fill hole.
(4) Install the fill hole plug (Fig. 5). Tighten the fill
hole plug to 48 Nzm (35 ft-lbs) torque.
(5) Remove the support and lower the vehicle.
FLUID DRAIN AND REFILL
The Transfer Case should be serviced as specified
in the Lubrication and Maintenance Schedules.
(1) Raise and support the vehicle.
(2) Remove the fill hole plug (Fig. 5) from the
transfer case.
(3) Place an appropriate container under the trans-
fer case drain hole plug (Fig. 5).
(4) Remove the drain hole plug and drain the ATF
from the transfer case into the container.
CAUTION: Do not over-tighten the drain and fill hole
plugs. Over-tightening can strip the hole threads
and/or crack the aluminum housing.
(5) Install the drain hole plug in the transfer case.
Tighten the drain hole plug to 27 Nzm (20 ft-lbs)
torque.
(6) Fill the transfer case to the bottom edge of the
fill hole.
(7) Install the fill hole plug in the transfer case
Tighten the plug to 27 Nzm (20 ft-lbs) torque.
(8) Remove the support and lower the vehicle.
FLUID SPECIFICATION
If it is necessary to add fluid to a transfer case (or
when the fluid is changed), use MOPAR ATF PLUS
type 7176 or an equivalent Mercon/Dexron III ATF.
FRONT AND REAR AXLES
The front and rear axles should be inspected for
fluid leaks and proper fluid level when other under
vehicle service is performed. Refer to the Lubrication
and Maintenance Schedule service intervals.
LUBRICANT SPECIFICATIONS
For normal vehicle operation, use SAE 75W-90,
API Quality Grade GL-5 gear lubricant in all Jeep
front (4WD only) and rear axles. Vehicles equipped
with a Trac-Lok rear axle also require a friction mod-
ifier additive included with the gear lubricant.
When involved in trailer towing applications
use SAE 80W-140, API Quality Grade GL-5 gear
lubricant in the rear axle. XJ Vehicles equipped
with a class III trailer hitch require SAE 75W-
140 synthetic gear lubricant in the rear axle.
Fig. 4 Dipstick & ATF Level
Fig. 5 Transfer CaseÐTypical
0 - 24 LUBRICATION AND MAINTENANCEJ

ALIGNMENT MEASUREMENTS AND ADJUSTMENTS
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 several times. Always release the bumper in
the down position.Set the front end alignment to
specifications with the vehicle at its NOR-
MALLY RIDE HEIGHT.
CAMBER
The wheel camber angle is preset. This angle is not
adjustable and cannot be altered.
CASTER
Before checking the caster of the front axle for cor-
rect angle, be sure the axle is not bent or twisted.
Road test the vehicle, make left and right turns. If
the steering wheel returns to the center position un-
assisted, the caster angle is correct. If steering wheeldoes not return toward the center position unas-
sisted, an incorrect caster angle is probable.
Caster can be adjusted by installing the appropri-
ate size shims (Fig. 2, 3).Changing caster angle
will also change the front propeller shaft angle.
The propeller shaft angle has priority over
caster. Refer to Group 16, Propeller Shafts for
additional information.
TOE POSITIONÐXJ VEHICLES
The wheel toe position adjustment should be the fi-
nal adjustment.
(1) Start the engine if equipped with power steer-
ing. Turn wheels both ways before straightening the
Fig. 2 AdjustmentÐYJ Vehicles
Fig. 3 AdjustmentÐXJ Vehicles
Fig. 4 Steering LinkageÐXJ (LHD)
2 - 8 FRONT SUSPENSION AND AXLEJ

INSTALLATION
(1) Position the lower retainer and grommet on the
upper stud. Insert the shock absorber through the
shock tower hole.
(2) Install the lower bolts and nuts. Tighten nuts
to 23 Nzm (17 ft. lbs.) torque.
(3) Install the upper grommet and retainer on the
stud in the engine compartment. Install the nut and
tighten to 10 Nzm (8 ft. lbs.) torque.
COIL SPRING
REMOVAL
(1) Raise and support the vehicle. Position a hy-
draulic jack under the axle to support it.
(2) Remove the wheel if necessary.
(3) Mark and disconnect the front propeller shaft
from the axle.
(4) Disconnect the lower suspension arms from the
axle (Fig. 6).
(5) Disconnect the stabilizer bar link and shock ab-
sorber from the axle.
(6) Disconnect the track bar from the frame rail
bracket.(7) Disconnect the drag link from the pitman arm.
(8) Lower the axle until the spring is free from the
upper mount. Remove the coil spring clip (Fig. 6) and
remove the spring.
(9) Pull jounce bumper out of mount.
INSTALLATION
(1) Install jounce bumper into mount.
(2) Position the coil spring on the axle pad. Install
the spring clip and bolt (Fig. 6). Tighten bolt to 21
Nzm (16 ft. lbs.) torque.
(3) Raise the axle into position until the spring
seats in the upper mount.
(4) Connect the stabilizer bar links and shock ab-
sorbers to the axle bracket. Connect the track bar to
the frame rail bracket.
(5) Install the lower suspension arms to the axle.
DO NOT TIGHTEN AT THIS TIME.
(6) Install the front propeller shaft to the axle.
(7) Remove the supports and lower the vehicle.
(8) Tighten lower suspension arms nuts to 115 Nzm
(85 ft. lbs.) torque.
2 - 14 FRONT SUSPENSION AND AXLEJ

The shock absorber bushings do not require any
type of lubrication. Do not lubricate the bushings to
reduce bushing noise. Grease or mineral oil-base lu-
bricants will deteriorate the bushing rubber.
The shock absorbers are not refillable or adjustable.
If a malfunction occurs, the shock absorber must be
replaced. To test a shock absorber, hold it in an up-
right position and force the piston into and out of the
cylinder four or five times. The action throughout
each stroke should be smooth and even.
SHOCK ABSORBER
REMOVAL
(1) Remove the nut, retainer and grommet from the
upper stud on the frame bracket (Fig. 3).
(2) Raise and support the vehicle.
(3) Remove the nut, washers and bolt from the
shock absorber lower eye (Fig.3).
(4) Remove the shock absorber.
(5) Remove the remaining grommet and retainer
from the shock absorber stud.
INSTALLATION
(1) Position the lower retainer and grommet on the
upper stud. Insert the shock absorber through the
shock tower hole.
(2) Install the lower bolts and nuts. Tighten the
nuts to 61 Nzm (45 ft. lbs.) torque.
(3) Install the upper grommet and retainer on the
stud on the frame bracket. Install the nut and tighten
to 12 Nzm (9 ft. lbs.) torque.
LEAF SPRING
REMOVAL
(1) Raise the vehicle.
(2) Support the vehicle with jack stands placed un-
der the frame.
(3) Position a hydraulic jack under the axle. Raise
the axle to relieve the axle weight from the springs.
(4) Remove the stabilizer bar links attaching nut.
(5) Remove the nuts, the U-bolts and spring
bracket from the axle.
(6) Remove the nut and bolt that attaches the
spring front eye to the shackle (Fig. 3).
(7) Remove the nut and bolt from the spring rear
eye.
(8) Remove the spring from the vehicle.
The spring can be disassembled by removing
the spring clips and the center bolt. If the
spring bushings require replacement, refer to
the bushing removal and installation proce-
dures.
INSTALLATION
(1) Position the spring front eye in the shackle.
Loosely install the attaching bolt and nut. Do not
tighten at this time.
(2) Position the rear eye in the hanger bracket.
Loosely install the attaching bolt and nut (Fig. 3). Do
not tighten at this time.
(3) Position the axle. Install the spring bracket,
U-bolts and nuts (Fig. 3). Tighten the U-bolt nuts to
122 Nzm (90 ft. lbs.) torque.
(4) Attach the stabilizer bar links.
(5) Remove the hydraulic jack.
Fig. 2 Stabilizer BarFig. 3 Spring & Shock Absorber
2 - 16 FRONT SUSPENSION AND AXLEJ

AXLE NOISE/VIBRATION DIAGNOSIS
INDEX
page page
Driveline Snap........................... 19
Gear and Bearing Noise.................... 18
General Information....................... 18Low Speed Knock......................... 19
Vibration................................ 19
GENERAL INFORMATION
Axle bearing problem conditions are usually caused
by:
²Insufficient or incorrect lubricant
²Foreign matter/water contamination
²Incorrect bearing preload torque adjustment
²Incorrect backlash (to tight)
When serviced, the bearings must be cleaned thor-
oughly. They should be dried with lint-free shop tow-
els.Never dry bearings with compressed air.
This will overheat them and brinell the bearing
surfaces. This will result in noisy operation af-
ter repair.
Axle gear problem conditions are usually the result
of:
²Insufficient lubrication
²Incorrect or contaminated lubricant
²Overloading (excessive engine torque) or exceeding
vehicle weight capacity
²Incorrect clearance or backlash adjustment
Insufficient lubrication is usually the result of a
housing cover leak. It can also be from worn axle
shaft or pinion gear seals. Check for cracks or porous
areas in the housing or tubes.
Using the wrong lubricant will cause overheating
and gear failure. Gear tooth cracking and bearing
spalling are indicators of this.
Axle component breakage is most often the result
of:
²Severe overloading
²Insufficient lubricant
²Incorrect lubricant
²Improperly tightened components
Overloading occurs when towing heavier than rec-
ommended loads. Component breakage can occur
when the wheels are spun excessively. Incorrect lu-
bricant quantity contributes to breakage. Loose dif-
ferential components can also cause breakage.
Incorrect bearing preload or gear backlash will not
result in component breakage. Mis-adjustment will
produce enough noise to cause service repair before a
failure occurs. If a mis-adjustment condition is not
corrected, component failure can result.
Excessive bearing preload may not be noisy. This
condition will cause high temperature which can re-
sult in bearing failure.
GEAR AND BEARING NOISE
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant. Incorrect backlash, tooth contact, or worn/dam-
aged gears can cause noise.
Gear noise usually happens at a specific speed
range. The range is 30 to 40 mph, or above 50 mph.
The noise can also occur during a specific type of
driving condition. These conditions are acceleration,
deceleration, coast, or constant load.
When road testing, accelerate the vehicle to the
speed range where the noise is the greatest. Shift
out-of-gear and coast through the peak-noise range.
If the noise stops or changes greatly, check for insuf-
ficient lubricant. Incorrect ring gear backlash, or
gear damage can cause noise changes.
Differential side and pinion gears can be checked
by turning the vehicle. They usually do not cause
noise in straight-ahead driving. These gears are
loaded during vehicle turns. If noise does occur dur-
ing vehicle turns, the side or pinion gears could be
worn or damaged. A worn pinion gear mate shaft can
also cause a snapping or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion gear bear-
ings can all produce noise when worn or damaged.
Bearing noise can be either a whining, or a growling
sound.
Pinion gear bearings have a constant-pitch noise.
This noise changes only with vehicle speed. Pinion
bearing noise will be higher because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs the pinion rear bearing is
the source of the noise. If the bearing noise is heard
during a coast, front bearing is the source.
Worn, damaged differential bearings usually pro-
duce a low pitch noise. Differential bearing noise is
similar to pinion bearing. The pitch of differential
bearing noise is also constant and varies only with
vehicle speed.
2 - 18 FRONT SUSPENSION AND AXLEJ

SHIFT MOTORÐREMOVAL/DISASSEMBLY
(1) Disconnect the vacuum and wiring connector
from the shift housing.
(2) Remove indicator switch.
(3) Remove the shift motor housing cover, gasket
and shield from the housing (Fig. 11).
(4) Remove the E-clips from the shift motor hous-
ing and shaft. Remove shift motor and shift fork from
the housing (Fig. 12).
(5) Remove the O-ring seal from the shift motor
shaft.
(6) Clean and inspect all components. If any com-
ponent is excessively worn or damaged, it should be
replaced.
ASSEMBLY/INSTALLATION
(1) Install a new O-ring seal on the shift motor
shaft.
(2) Insert the shift motor shaft through the hole in
the housing and shift fork. The shift fork offset
should be toward the differential.(3) Install the E-clips on the shift motor shaft and
housing.
(4) Install the shift motor housing gasket and
cover.Ensure the shift fork is correctly guided
into the shift collar groove.
(5) Install the shift motor housing shield and at-
taching bolts. Tighten the bolts to 11 Nzm (101 in.
lbs.) torque.
(6) Add 148 ml (5 ounces) of API grade GL 5 hy-
poid gear lubricant to the shift motor housing. Add
lubricant through indicator switch mounting hole.
(7) Install indicator switch, electrical connector
and vacuum harness.
INTERMEDIATE AXLE SHAFTÐREMOVAL/
DISASSEMBLY
Service to the Disconnect axle seals and bearing re-
quire the use of Tool Set 6288 (J34659) and Seal In-
staller 6228.
(1) Remove the vacuum motor housing. Refer to
Shift Motor Removal in this section.
(3) Remove the outer axle shaft. Refer to Hub
Bearing and Axle Shaft in this section.
(4) Remove shift collar and intermediate axle
shaft.
(5) Remove the inner axle shaft seal from the shift
motor housing (Fig. 13).
(6) Remove the intermediate axle shaft bearing
(Fig. 14).
ASSEMBLY/INSTALLATION
(1) Position the bearing on installation tool. Seat
the bearing in the housing bore (Fig. 15).
(2) Clean the inside perimeter of the axle shaft
tube with fine crocus cloth.
(3) Apply a light film of oil to the inside lip of the
new axle shaft seal.
(4) Install the inner axle seal (Fig. 16, 17).
The axle shaft seal primary installation tool
6228-1 will only force the seal partially into the
Fig. 11 Shift Motor Housing and Shift Collar
Fig. 12 Vacuum Shift Motor ComponentsFig. 13 Axle Shaft Inner Seal Removal
JFRONT SUSPENSION AND AXLE 2 - 31

(3) Drive out pinion gear from housing with raw-
hide or plastic hammer (Fig. 33). Catch the pinion
with your hand to prevent it from falling and being
damaged.This will damage the front bearing
rollers and bearing cup. The front bearing and
cup must be replaced.Remove preload shims and
record the thickness.
(4) Remove front bearing from housing.
(5) Remove the front pinion bearing cup and seal
with Remover D-147 and Handle C-4171 (Fig. 34).
(6) Remove the rear bearing cup from housing (Fig.
35). Use Remover D-149 and Handle C-4171.
(7) Remove the inner bearing from the pinion with
Puller C-293-PA and Adapter C-293-39 (Fig. 36).
Place adapter rings so they do not damage
the bearing cage.(8) Remove the oil slinger from the pinion gear
shaft.Save the slinger it is used as select shim
for pinion depth.
CLEANING/INSPECTION
Wash differential components with cleaning solvent
and dry with compressed air.Do not steam clean
the differential components.
Wash bearings with solvent and towel dry, or dry
with compressed air. DO NOT spin bearings with
Fig. 31 Pinion Mate Gear Removal
Fig. 32 Pinion Yoke Removal
Fig. 33 Remove Pinion Gear
Fig. 34 Front Bearing Cup Removal
JFRONT SUSPENSION AND AXLE 2 - 37