boot JEEP XJ 1995 Service And Owner's Manual

SHIFT LINKAGE ADJUSTMENT
(1) Shift transfer case into 4L position.
(2) Raise vehicle.
(3) Loosen lock bolt on adjusting trunnion (Figs. 3
and 4).
4) Be sure linkage rod slides freely in trunnion.
Clean rod and apply spray lube if necessary.
(5) Verify that transfer case range lever is fully en-
gaged in 4L position.
(6) Tighten adjusting trunnion lock bolt.
(7) Lower vehicle.
SHIFT LEVER REMOVAL (XJ)
(1) Shift transfer case into 4L.
(2) Raise vehicle.
(3) Loosen adjusting trunnion locknut and slide
shift rod out of trunnion (Fig. 4). If rod lacks enough
travel to come out of trunnion, push trunnion out of
torque shaft.
(4) Lower vehicle.
(5) Remove console. Refer to park brake section in
Group 5 for procedures.
(6) Remove screws attaching lever assembly to
floorpan and remove assembly and shift rod (if left
attached).
SHIFT LEVER INSTALLATION (XJ)
(1) If shift rod was not removed from lever assem-
bly, work rod down through floorpan opening. Then
position lever assembly on floorpan and install as-
sembly attaching screws.
(2) Install console.
(3) Raise vehicle.
(4) Connect trunnion to torque shaft arm. Or, slide
shift rod into trunnion on range lever. Be sure shift
rod slides freely in trunnion.
(5) Verify that range lever is in 4L position. Then
tighten trunnion lock bolt.(6) Lower vehicle and check transfer case shift op-
eration.
SHIFT LEVER REMOVAL (YJ)
(1) Shift transfer case into neutral.
(2) Remove shift lever knob and retaining nut.
Then remove shift lever boot and bezel.
(3) Raise vehicle
(4) Loosen lock bolt in adjusting trunnion and slide
shift rod out of trunnion (Fig. 3).
(5) Remove bolts/nuts attaching bracket and brace
assembly to transmission (Fig. 5).
(6) Remove shift lever and bracket as assembly.
(7) YJ shift lever assembly is serviceable. If any
assembly part must be replaced, remove pivot bolt,
lever pin E-clip, and lever pin and spring. Then dis-
assemble and replace necessary part (Fig. 6).
SHIFT LEVER INSTALLATION (YJ)
(1) Assemble lever components, if necessary. Lube
pivot bolt and pin with Mopar multi-mileage grease
before installation.
(2) Work shift lever upward into vehicle interior.
Then position lever and bracket assembly on trans-
mission and install attaching bolts/nuts.
(3) Place transfer case range lever in 4L position.
Then slide shift rod into trunnion and tighten lock
bolt.
Fig. 3 Adjusting Trunnion And Lock Bolt (YJ)
Fig. 4 Shift Linkage (XJ)
21 - 286 NP231 TRANSFER CASEJ

(4) Lower vehicle.
(5) Install shift lever bezel and boot (Fig. 7). Then
install retaining nut and shift knob on lever.
SPEEDOMETER SERVICE
Speedometer service is covered in the 30RH/32RH,
or AW-4 automatic transmission sections in this
group. Refer to the appropriate section as needed.
TRANSFER CASE REMOVAL
(1) Shift transfer case into Neutral.
(2) Raise vehicle.
(3) Drain transfer case lubricant.
(4) Mark front and rear propeller shaft yokes for
alignment reference.
(5) Support transmission with jack stand.
(6) Remove rear crossmember, or skid plate.
(7) Disconnect front/rear propeller shafts at trans-
fer case.
(8) Disconnect vehicle speed sensor wires.
(9) Disconnect transfer case linkage rod from range
lever.
(10) Disconnect transfer case vent hose, and indi-
cator or vacuum switch harness.
(11) Support transfer case with transmission jack.
(12) Remove nuts attaching transfer case to trans-
mission.
(13) Secure transfer case to jack with chains.
Fig. 5 Shift Linkage Mounting (YJ)
Fig. 6 Shift Linkage (YJ)
JNP231 TRANSFER CASE 21 - 287

(14) Pull transfer case and jack rearward to disen-
gage transfer case.
(15) Remove transfer case from under vehicle.
(16) If transfer case was removed for overhaul, re-
move damper from rear retainer.
TRANSFER CASE INSTALLATION
(1) Mount transfer case on a transmission jack. Se-
cure transfer case to jack with chains.
(2) Position transfer case under vehicle.(3) Align transfer case and transmission shafts and
install transfer case on transmission.
(4) Install and tighten transfer case attaching nuts
to 35 Nzm (26 ft. lbs.) torque.
(5) Install damper on rear retainer (Fig. 8).
Tighten damper attaching nuts to 54 Nzm (40 ft. lbs.)
torque.
(6) Connect vehicle speed sensor wires, and vent
hose.
(7) Connect indicator or vacuum switch harness to
transfer case switch. Secure wire harnesses to clips
on transfer case.
(8) Align and connect propeller shafts. Tighten
shaft attaching bolts to 19 Nzm (170 in. lbs.) torque.
(9) Fill transfer case with Mopar Dexron II fluid.
(10) Install rear crossmember, or skid plate.
Tighten crossmember bolts to 41 Nzm (30 ft. lbs.)
torque.
(11) Remove transmission jack and support stand.
(12) Connect shift rod to transfer case range lever.
(13) Adjust transfer case shift linkage.
(14) Lower vehicle and verify transfer case shift
operation.
Fig. 7 Transfer Case Shift Lever And Boots (YJ)
Fig. 8 Transfer Case Mounting
21 - 288 NP231 TRANSFER CASEJ

(2) Position the waterdam on door inner panel (Fig. 20).
(3) If removed, install the storage bin panel and
speaker grille on the front door trim panel.
(4) If removed, install the ash receiver tray hous-
ing on the rear door trim panel.
(5) Position the trim panel on the door inner panel
and press the retainers inward.
(6) Install the armrest and window glass regulator
handle. Or (if equipped) the power window switches
and bezel. Tighten the armrest screws to 4 Nzm (34
in-lbs) torque.
(7) Connect the rods to the inside latch release han-
dle and install the handle. Tighten the screws to 2 Nzm
(16 in-lbs) torque. For vehicles with power door locks/
windows, connect the wire harness connector.
DOOR REMOVAL/INSTALLATIONÐXJ
REMOVAL
(1) Remove the door restraint (check) retaining pin
(Fig. 1) with a punch.
(2) For vehicles equipped with power windows and
power door locks, remove the trim panel and discon-
nect all components. Slide the wire harness out of
the boot and door (Fig. 2, 3, 4, 5 and 6)
Fig. 1 Door Restraint Retaining Pin
Fig. 20 Waterdam Installation
Fig. 2 Right Front Door Wire Harness Connectors
Fig. 3 Right Front Door Wire Harness ConnectorsÐ
With Security Alarm Switch
JDOORSÐXJ 23 - 35

CARPETS AND FLOOR MATSÐXJ
The carpets/mats are retained around the perime-
ter of the floor panel by the interior trim moldings
and trim panels. To remove a carpet/mat, all of the
retaining trim moldings and panels must be removed
along with all the interfering components (as appli-
cable):
²Seat(s).
²Parking brake lever cover.
²Floor console.
²Transmission and transfer case (if equipped) floor
shift cover/boot.
If necessary, refer to the applicable removal proce-
dure(s) within this manual.
FRONT CARPET/MATÐXJ
REMOVAL
(1) Remove the door sill inner scuff plates.
(2) Remove the front and rear seats (as applicable).
(3) As necessary, remove the trim panels and mold-
ings.
(4) Remove all other interfering components.
(5) Remove the carpet and mat from the floor
panel (Fig. 6).
INSTALLATION
(1) Position the carpet and mat on the floor panel.(2) Install all the components that were removed
to facilitate carpet/mat removal.
(3) Install the trim panels and moldings.
(4) Install the door sill inner scuff plates.
(5) Install the front and rear seats (as applicable).
Fig. 5 Spare Tire/Wheel Holddown Bolt and Bracket (RHD)
Fig. 6 Front Carpet and Mat
JINTERIOR COMPONENTSÐXJ 23 - 99

CARPETÐYJ
PASSENGER COMPARTMENT FRONT CARPET
SECTION
The passenger compartment front carpet section
(Fig. 1) is retained in place by the:
²Transmission/transfer case shift lever boots (Fig.
2).
²Passenger compartment rear carpet section.
²Velcro strips.
To remove and install a front carpet section (Fig.
1), it is necessary to remove and then install the shift
lever boots (Fig. 2).
Refer to the applicable component removal/installa-
tion procedures in this group.
When replacing a front carpet, position and cut
openings in carpet with a razor knife for shift levers
and boots (Fig. 2).
PASSENGER COMPARTMENT REAR CARPET
SECTION
The rear floor carpet section in the passenger com-
partment (Fig. 1) is retained in place by the:
²Front seats.
²Floor console.
²Shoulder belt buckle anchors.
²Door sill carpets.
To remove and then install the rear carpet section
(Fig. 1), it is necessary to remove and then install the
front seats and the floor console.
Refer to the applicable component removal/installa-
tion procedures in this group.
CARGO FLOOR CARPET
The cargo floor carpet (Fig. 1) is retained in place
by the:
²Rear seat.
²Shoulder belt buckle anchors.
²Wheelhouse carpets.
To remove and then install a cargo floor carpet, it
is necessary to remove and then install the rear seat.
Refer to the applicable component removal/installa-
tion procedures in this group.
WHEELHOUSE, DOOR SILL AND TAILGATE
CARPETS
The wheelhouse, door sill and tailgate carpets (Fig.
3) are retained in place with:
²Adhesive.
²Velcro strips.
²Screws.
Fig. 8 Console Cover Lock Removal/Installation
Fig. 1 Floor Carpets
Fig. 2 Shift Lever Boots
23 - 156 INTERIOR COMPONENTSÐYJJ