lug pattern JEEP YJ 1995 Service And User Guide

(8) Lower the vehicle.
(9) Install the engine cylinder head, push rods,
rocker arms, bridges, pivots and engine cylinder head
cover.
(10) Fill the crankcase with engine oil.
CRANKSHAFT MAIN BEARINGS
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the spark plugs.
(3) Raise the vehicle.
(4) Remove the oil pan and oil pump.
(5) Remove only one main bearing cap and lower
insert at a time (Fig. 1).
(6) Remove the lower insert from the bearing cap.
(7) Remove the upper insert by LOOSENING (DO
NOT REMOVE) all of the other bearing caps. Now
insert a small cotter pin tool in the crankshaft jour-
nal oil hole. Bend the cotter pin as illustrated to fab-
ricate the tool (Fig. 2). With the cotter pin tool in
place, rotate the crankshaft so that the upper bear-
ing insert will rotate in the direction of its locking
tab. Because there is no hole in the No.3 main jour-
nal, use a tongue depressor or similar soft-faced tool
to remove the bearing insert (Fig. 2). After moving
the insert approximately 25 mm (1 inch), it can be
removed by applying pressure under the tab.
(8) Using the same procedure described above, re-
move the remaining bearing inserts one at a time for
inspection.
INSPECTION
Wipe the inserts clean and inspect for abnormal
wear patterns and for metal or other foreign material
imbedded in the lining. Normal main bearing insert
wear patterns are illustrated (Fig. 3).
If any of the crankshaft journals are scored,
remove the engine for crankshaft repair.
Inspect the back of the inserts for fractures, scrap-
ings or irregular wear patterns.
Inspect the upper insert locking tabs for damage.
Replace all damaged or worn bearing inserts.
FITTING (CRANKSHAFT INSTALLED)
The main bearing caps, numbered (front to rear)
from 1 through 7 have an arrow to indicate the for-
Fig. 1 Removing Main Bearing Caps and Lower
Inserts
Fig. 2 Removing Upper Inserts
Fig. 3 Main Bearing Wear Patterns
J4.0L ENGINE 9 - 87

TRANSMISSION IDENTIFICATION
The AX 4/5 identification code is on the bottom sur-
face of the transmission case near the fill plug (Fig. 2).
The first number is year of manufacture. The second
and third numbers indicate month of manufacture. The
next series of numbers is the transmission serial num-
ber.
GEAR RATIOS
Gear ratios for the AX 4 and AX 5 are as follows:
²First gear: 3.93:1
²Second gear: 2.33:1
²Third gear: 1.45:1
²Fourth gear: 1.00:1
²Fifth gear (AX 5): 0.85:1
²Reverse gear: 4.74:1
SHIFT PATTERN
The AX 4/5 first through fourth gear shift pattern
is in a conventional H configuration. On the AX 5,
fifth gear is up and to the right and reverse gear is
down and to the right (Fig. 3).
RECOMMENDED LUBRICANT
Recommended lubricant for AX 4/5 transmissions is
Mopar 75W-90, API Grade GL-5 gear lubricant, or
equivalent.
Correct lubricant level is from the bottom edge, to
no more than 6 mm (1/4 in.) below the bottom edge of
the fill plug hole.
The fill plug is at the passenger side of the adapter
housing Fig. 4). The drain plug is at the bottom of
the case.
Approximate dry fill lubricant capacity is 3.3 liters
(3.5 qts.).
SERVICE DIAGNOSIS
LOW LUBRICANT LEVEL
A low transmission lubricant level is generally the
result of a leak, inadequate lubricant fill, or an incor-
rect lubricant level check.
Leaks can occur at the mating surfaces of the gear
case, intermediate plate and adaptor or extension
housing, or from the front/rear seals. A suspected
leak could also be the result of an overfill condition.
Leaks at the rear of the extension or adapter hous-
ing will be from the housing oil seals. Leaks at com-
ponent mating surfaces will probably be the result of
inadequate sealer, gaps in the sealer, incorrect bolt
tightening, or use of a non-recommended sealer.
A leak at the front of the transmission will be from
either the front bearing retainer or retainer seal. Lu-
bricant may be seen dripping from the clutch housing
after extended operation. If the leak is severe, it may
also contaminate the clutch disc causing slip, grab
and chatter.
Transmissions filled from air or electrically powered
lubricant containers can be underfilled. This generally
Fig. 2 Transmission Identification
Fig. 3 AX 4/5 Shift Pattern
Fig. 4 Fill Plug Location
21 - 2 AX 4/5 MANUAL TRANSMISSIONJ

AX 15 MANUAL TRANSMISSION
INDEX
page page
General Information....................... 33
Service Diagnosis......................... 34
Transmission Assembly and Adjustment......... 52
Transmission Disassembly and Overhaul........ 37
Transmission Gear Ratios................... 34
Transmission Identification.................. 33Transmission Installation.................... 36
Transmission Lubricant..................... 34
Transmission Removal..................... 35
Transmission Shift Pattern................... 34
Transmission Switch and Plug Locations........ 34
GENERAL INFORMATION
The AX 15 is a 5-speed, synchromesh, manual
transmission. Fifth gear is an overdrive range with a
ratio of 0.79:1. The shift mechanism is integral and
mounted in the shift tower portion of the adapter
housing (Fig. 1).
An adapter housing is used to attach the transmis-
sion to the transfer case on 4-wheel drive models. A
standard extension housing is used on 2-wheel drive
models.
The AX 15 is used in XJ and YJ models with a 4.0L
engine. The AX 15 is used for two and four-wheel
drive applications.
TRANSMISSION IDENTIFICATION
The AX 15 identification code numbers are on the
bottom surface of the transmission gear case (Fig. 2).
Fig. 1 AX 15 Manual Transmission
Fig. 2 Identification Code Number Location
JAX 15 MANUAL TRANSMISSION 21 - 33

The first number is year of manufacture. The sec-
ond and third numbers indicate month of manufac-
ture. The next series of numbers is the transmission
serial number.
TRANSMISSION SHIFT PATTERN
The AX 15 shift pattern is shown in Figure 3. First
and second and third and fourth gear ranges are in
line for improved shifting. Fifth and reverse gear
ranges are also in line at the extreme right of the
pattern (Fig. 3).
The AX 15 is equipped with a reverse lockout
mechanism. The shift lever must be moved through
the Neutral detent before making a shift to reverse.
TRANSMISSION LUBRICANT
Recommended lubricant for AX 15 transmissions is
Mopar 75W-90, API Grade GL-5 gear lubricant, or
equivalent.
Correct lubricant level is from the bottom edge, to
no more than 6 mm (1/4 in.) below the bottom edge of
the fill plug hole.
Approximate dry fill lubricant capacity is:
²3.10 liters (3.27 qts.) in 4-wheel drive models
²3.15 liters (3.32 qts.) in 2-wheel drive models
TRANSMISSION SWITCH AND PLUG LOCATIONS
The fill plug is at the driver side of the gear case
(Fig. 4).
The drain plug and backup light switch are on the
passenger side of the gear case (Fig. 5).
TRANSMISSION GEAR RATIOS
AX 15 gear ratios are:
First gear - 3.83:1
Second gear - 2.33:1
Third gear - 1.44:1
Fourth gear - 1.00:1
Fifth gear - 0.79:1
Reverse - 4.22:1
SERVICE DIAGNOSIS
LOW LUBRICANT LEVEL
A low transmission lubricant level is generally the
result of a leak, inadequate lubricant fill, or an incor-
rect lubricant level check.
Leaks can occur at the mating surfaces of the gear
case, intermediate plate and adapter or extension
housing, or from the front/rear seals. A suspected
leak could also be the result of an overfill condition.
Leaks at the rear of the extension or adapter hous-
ing will be from the housing oil seals. Leaks at com-
ponent mating surfaces will usually be the result of
inadequate sealer, gaps in the sealer, incorrect bolt
tightening, or use of a non-recommended sealer.
A leak at the front of the transmission will be from
either the front bearing retainer or retainer seal. Lu-
bricant may be seen dripping from the clutch housing
after extended operation. If the leak is severe, it may
also contaminate the clutch disc causing slip, grab
and chatter.
Transmissions filled from air or electrically pow-
ered lubricant containers can be underfilled. This
Fig. 3 AX 15 Shift Pattern
Fig. 4 Fill Plug Location
Fig. 5 Drain Plug/Backup Light Switch Location
21 - 34 AX 15 MANUAL TRANSMISSIONJ

VALVE BODY ASSEMBLY AND ADJUSTMENT
CAUTION: Do not force valves or plugs into place
during reassembly. If the valve body bores, valves
and plugs are free of distortion or burrs, the valve
body components should all slide into place easily.
In addition, do not overtighten the transfer plate
and valve body screws during reassembly. Over-
tightening can distort the valve body resulting in
valve sticking, cross leakage and unsatisfactory op-
eration. Tighten valve body screws to recom-
mended torque only.
(1) Lubricate valve body bores, valves and plugs
with Mopar ATF Plus transmission fluid.
(2) Insert rear clutch and rear servo check balls in
transfer plate (Fig. 120).
(3) Install filter screen in separator plate (Fig.
120).
(4) Align and install separator plate on transfer
plate. Verify check ball position before installing sep-
arator plate on transfer plate.
(5) Install new O-ring on converter clutch solenoid
and insert solenoid in separator plate (Fig. 120).
Then secure solenoid in position with attaching
screw. Tighten screw to 4 Nzm 35 in. lbs.) torque.
(6) Position valve body so internal passages and
check ball seats are facing upward. Then install
check balls in valve body (Fig. 121). There are a total
of seven check balls; The one large check ball is ap-
proximately 11/32 inch in diameter. The remaining
check balls are approximately 1/4 inch in diameter.
Note that check balls will be steel on some very early
production models and plastic on later production
models.
(7) Align and install assembled transfer and sepa-
rator plates on valve body. Install and tighten valve
body screws alternately in a diagonal pattern to 4
Nzm (35 in. lbs.) torque.
(8) Assemble and install lockup module and compo-
nents on valve body (Fig. 122).
(9) Assemble regulator valve line pressure plug,
sleeve, throttle plug and spring (Fig. 113). Insert as-sembly in valve body and install end plate. Tighten
end plate screws to 4 Nzm (35 in. lbs.) torque.
(10) Install 1-2 and 2-3 shift valves and springs
(Fig. 118).
(11) Install 1-2 shift control valve and spring (Fig.
118)
(12) Install shuttle valve as follows:
(a) Insert shuttle valve in bore.
(b) Insert plastic guides in shuttle valve second-
ary spring.
(c) Install spring on end of valve.
(d) Hold shuttle valve in place. Then compress
secondary spring and install E-clip in groove at end
of valve.
(e) Verify that spring and E-clip are properly
seated before proceeding.
(13) Install shuttle valve cover plate (Fig. 118).
Tighten end plate screws to 4 Nzm (35 in. lbs.)
torque.
(14) Install 1-2 and 2-3 valve governor plugs in
valve body (Fig. 113). Then install shuttle valve pri-
mary spring and throttle plug.
(15) Align and install governor plug end plate on
valve body and install end plate screws. Tighten
screws to 4 Nzm (35 in. lbs.) torque.
(16) Install manual valve (Fig. 117).
(17) Install throttle valve and spring. Then install
kickdown valve and detent (Fig. 117).
(18) Install pressure regulator valve and switch
valve in valve body.
(19) Install manual lever detent spring in housing.
Place detent ball on end of spring and push ball and
spring into housing. Secure ball and spring with De-
tent Retainer 6583 (Fig. 108).
Fig. 120 Installing Converter Clutch Solenoid
Fig. 121 Correct Position Of Valve Body Check Balls
J30RH/32RH TRANSMISSION OVERHAUL 21 - 153

(6) Verify that reaction shaft support hub seal
rings are hooked together (Fig. 155).
(7) Coat front clutch thrust washer with petroleum
jelly to hold it in place. Then install washer over re-
action shaft hub and seat it on pump (Fig. 156).
CAUTION: The thrust washer bore (I.D.), is cham-
fered on one side. Make sure the chamfered side is
installed so it faces the pump.(8) Thread two Pilot Stud Tools C-3288-B into bolt
holes in oil pump flange (Fig. 157).
(9) Align and install oil pump gasket (Fig. 157).
(10) Lubricate oil pump seals with Mopar Door-
Ease, or Ru-Glyde, Door Eze, or ATF Plus.
(11) Install oil pump (Fig. 158). Align and position
pump on pilot studs. Slide pump down studs and
work it into front clutch hub and case by hand. Then
install two or three pump bolts to hold pump in
place.
(12) Remove pilot stud tools and install remaining
oil pump bolts. Tighten bolts alternately in diagonal
pattern to 20 Nzm (15 ft-lbs).
CHECKING INPUT SHAFT END PLAY
(1) Measure input shaft end play (Fig. 159).
(2) Attach dial indicator to converter housing. Po-
sition indicator plunger against input shaft and zero
indicator.
Fig. 153 Front Band Linkage Installation
Fig. 154 Installing Front Band Pivot Pin Access Plug
Fig. 155 Reaction Shaft Support Seal Rings
Fig. 156 Front Clutch Thrust Washer Installation
Fig. 157 Installing Pilot Studs And Oil Pump Gasket
21 - 162 30RH/32RH TRANSMISSION OVERHAULJ

OPERATING RANGES
NP231 operating ranges are: 2-wheel drive high;
4-wheel drive high and 4-wheel drive low.
2-wheel drive range is for use on all road surfaces.
The 4-wheel drive high and low ranges are undiffer-
entiated and should only be used on unpaved, low
traction surfaces only. The only exception being when
hard surface roads are snow and ice covered.
SHIFT MECHANISM
Operating ranges are selected with a floor mounted
shift lever. The shift lever is connected to the trans-
fer case range lever by an adjustable linkage rod. A
straight line shift pattern is used. Range positions
are marked on the shifter bezel cover plate, or on the
shift knob.
TRANSFER CASE IDENTIFICATION
A circular ID tag is attached to the rear case of
each NP231 transfer case (Fig. 2). The ID tag pro-
vides the transfer case model number, assembly
number, serial number and low range ratio.
The transfer case serial number also represents the
date of build. For example, a serial number of
7-10-94 would represent July 10, 1994.TRANSFER CASE LUBRICANT AND FILL LEVEL
Recommended lubricant for the NP231 transfer
case is Mopar Dexron II.
Approximate lubricant refill capacity is 1.54 liters
(3.25 pints) for YJ and 1.04 liters (2.2 pints) for XJ.
Correct fill level is to the bottom edge of the fill
plug hole. Be sure the vehicle is level to ensure an
accurate fluid level check.
Fig. 2 Transfer Case Identification Tag
21 - 284 NP231 TRANSFER CASEJ

WHEELS
GENERAL INFORMATION
Original equipment wheels are designed for the
specified Maximum Vehicle Capacity.
All models use steel or cast aluminum drop center
wheels. The safety rim wheel (Fig. 1) has raised sec-
tions between the rim flanges and the rim well.
Initial inflation of the tire forces the bead over
these raised sections. In case of tire failure, the
raised sections hold the tire in position on the wheel
until the vehicle can be brought to a safe stop.
Cast aluminum wheels require special balance
weights and alignment equipment.
WHEEL INSTALLATION
The wheel studs and nuts are designed for specific
applications. They must be replaced with equivalent
parts. Do not use replacement parts of lesser quality
or a substitute design. All aluminum and some steel
wheels have wheel stud nuts which feature an en-
larged nose. This enlarged nose is necessary to en-
sure proper retention of the aluminum wheels.
Before installing the wheel, be sure to remove any
build up of corrosion on the wheel mounting surfaces.
Ensure wheels are installed with good metal-to-metal
contact. Improper installation could cause loosening
of wheel nuts. This could affect the safety and han-
dling of your vehicle.
To install the wheel, first position it properly on
the mounting surface. All wheel nuts should then be
tightened just snug. Gradually tighten them in se-
quence to 129 Nzm (95 ft. lbs.) torque (Fig. 2).Never
use oil or grease on studs or nuts.
WHEEL REPLACEMENT
Wheels must be replaced if they have:²Excessive runout
²Bent or dented
²Leak air through welds
²Have damaged bolt holes
Wheel repairs employing hammering, heating, or
welding are not allowed.
Original equipment wheels are available through
your dealer. Replacement wheels from any other
source should be equivalent in:
²Load carrying capacity
²Diameter
²Width
²Offset
²Mounting configuration
Failure to use equivalent replacement wheels may
affect the safety and handling of your vehicle. Re-
placement withusedwheels is not recommended.
Their service history may have included severe treat-
ment.
Refer to the Specifications Chart for informa-
tion regarding above requirements.
WHEEL ORNAMENTATION
WARNING: HANDLE ALL WHEEL ORNAMENTATION
WITH EXTREME CARE DURING REMOVAL AND IN-
STALLATION. SHARP EDGES ON THE COVERS OR
CAPS CAN CAUSE PERSONAL INJURY.
TIRE AND WHEEL BALANCE
It is recommended that a two plane dynamic bal-
ancer be used when a wheel and tire assembly re-
quire balancing. Static should be used only when a
two plane balancer is not available.
For static imbalance, find location of heavy spot
causing imbalance. Counter balance wheel directly
Fig. 1 Wheel Safety Rim
Fig. 2 Lug Nut Tightening Pattern
22 - 6 WHEELS AND TIRESJ

ANTENNA........................8F-2,8F-5
ANTENNA, POWER; RADIO (XJ-RHD) . . . 8W-47-1
ANTENNA REMOVE/INSTALL - XJ.........8F-8
ANTENNA REMOVE/INSTALL - YJ........8F-10
ANTILOCK BRAKES (ABS)................5-1
ANTILOCK BRAKING MODE, ABS
OPERATION IN.......................5-36
ANTILOCK ECU AND HCU DIAGNOSIS......5-3
APPLICATION CHARTS, GEARTRAIN
OPERATION........................21-169
APPLICATION, TRANSMISSION..........21-67
APPLICATIONÐXJ VEHICLES, BULB......8L-18
APPLICATIONÐYJ VEHICLES, BULB......8L-32
APPLIQUEÐXJ, QUARTER WINDOW.....23-25
APPLIQUEÐYJ, RADIATOR GRILLE.....23-104
APRONSÐYJ, FENDER SPLASH........23-115
ARM, LOWER SUSPENSION.............2-13
ARM, PITMAN..................19-17,19-20
ARM REMOVE/INSTALL, LIFTGATE
WIPER.............................8K-17
ARM REMOVE/INSTALL, WINDSHIELD
WIPER.............................8K-17
ARM, UPPER SUSPENSION.............2-12
ARMING/DISARMING MECHANISM;
RESTRAINT SYSTEMS.................8M-2
ARMING/DISARMING MECHANISM;
STEERING..........................19-48
ARMS AND PUSH RODS, ROCKER....9-23,9-65
ASH RECEIVER TRAY LAMPÐXJ, I/P.....23-80
ASSEMBLY....................19-63,19-71
ASSEMBLY AND ADJUSTMENT, VALVE
BODY.............................21-153
ASSEMBLY, CALIPER...................5-50
ASSEMBLY, COMPRESSOR CLUTCH......24-20
ASSEMBLY, DIFFERENTIAL; FRONT
SUSPENSION AND AXLE................2-38
ASSEMBLY, DIFFERENTIAL; REAR
SUSPENSION AND AXLES...............3-21
ASSEMBLY, FINAL; FRONT SUSPENSION
AND AXLE...........................2-46
ASSEMBLY, FINAL; REAR SUSPENSION
AND AXLES..........................3-29
ASSEMBLY, FUEL RAIL................14-62
ASSEMBLY, GEAR....................19-43
ASSEMBLY, IMPACT SENSOR/INFLATOR . . . 8M-2
ASSEMBLY, PINION MEASUREMENT.......3-22
ASSEMBLY REMOVE/INSTALL, CLUSTER . . 8E-17,
8E-35
ASSEMBLY REPLACEMENT, ADJUSTER
PLUG..............................19-29
ASSEMBLY REPLACEMENT, COLUMN.....19-52
ASSEMBLY REPLACEMENTÐXJ
VEHICLES, DRIVE AXLE; FRONT
SUSPENSION AND AXLE................2-23
ASSEMBLY REPLACEMENTÐXJ
VEHICLES, DRIVE AXLE; REAR
SUSPENSION AND AXLES...........3-14,3-31
ASSEMBLY REPLACEMENTÐYJ
VEHICLES, DRIVE AXLE; FRONT
SUSPENSION AND AXLE................2-24
ASSEMBLY REPLACEMENTÐYJ
VEHICLES, DRIVE AXLE; REAR
SUSPENSION AND AXLES...............3-14
ASSEMBLY (SHORT BLOCK), SERVICE
ENGINE..............................9-4
ASSEMBLY TIPS, TRANSMISSION......21-155
ASSEMBLY, TRANSFER CASE
....21-294,21-319
ASSEMBLY/INSTALLATION, PINION GEAR
. . 2-42
ASSEMBLYÐXJ VEHICLES, ENGINE
. . . 9-18,9-59
ASSEMBLYÐYJ VEHICLES, ENGINE
. . . 9-20,9-62
ASSIST HANDLEÐXJ
.................23-89
ASSIST HANDLEÐYJ, FULL-METAL
DOOR
............................23-136
AUTO SHUTDOWN (ASD) RELAYÐPCM
OUTPUT
............................14-26
AUTOMATIC BELT TENSIONERÐXJ
MODELS WITH RIGHT HAND DRIVE
.......7-42
AUTOMATIC SHUT DOWN (ASD) RELAY;
FUEL/IGNITION (XJ)
................8W-30-1
AUTOMATIC SHUT DOWN (ASD) RELAY;
FUEL/IGNITION (YJ)
................8W-30-1
AUTOMATIC SHUT DOWN (ASD) RELAY;
FUEL/IGNITION (XJ-RHD)
............8W-30-1
AUTOMATIC SHUTDOWN (ASD) RELAY;
FUEL SYSTEM
.......................14-59
AUTOMATIC SHUTDOWN (ASD) RELAY;
IGNITION SYSTEMS
..............8D-17,8D-1AUTOMATIC SHUTDOWN (ASD) RELAY
TEST...............................8D-6
AUTOMATIC SHUTDOWN (ASD) RELAY
TESTING...........................14-46
AUTOMATIC SHUTDOWN (ASD)
SENSEÐPCM INPUT..................14-21
AUTOMATIC TRANSMISSION............0-23
AUTOMATIC TRANSMISSION, 30RH/
32RH..............................21-67
AUTOMATIC TRANSMISSION, AW-4.....21-165
AUTOMATIC TRANSMISSION SHIFTER/
IGNITION INTERLOCK MECHANISM......19-55
AUXILIARY ELECTRIC COOLING FANÐXJ
MODELS WITH 4.0L 6-CYLINDER
ENGINE.............................7-35
AW-4 ACCUMULATOR COMPONENT
IDENTIFICATION....................21-342
AW-4 AUTOMATIC TRANSMISSION......21-165
AW-4 BUSHING AND PISTON
CLEARANCE........................21-339
AW-4 CLUTCH AND BRAKE PACK
REQUIREMENTS....................21-341
AW-4 CLUTCH DISC AND PLATE
THICKNESS........................21-338
AW-4 GENERAL SPECIFICATIONS.......21-337
AW-4 IN-VEHICLE SERVICE............21-182
AW-4 OIL PUMP WEAR LIMITS........21-338
AW-4 RETAINER AND PISTON
SPECIFICATIONS....................21-340
AW-4 TORQUE SPECIFICATIONS........21-344
AW-4 TRANSMISSION DIAGNOSIS......21-176
AW-4 TRANSMISSION OVERHAUL......21-201
AW-4 TRANSMISSION REMOVAL AND
INSTALLATION......................21-198
AW-4 VALVE AND SPRING
IDENTIFICATION....................21-343
AW-4 VALVE BODY CHECK BALL
DIMENSIONS.......................21-341
AWAY, PEDAL FALLS....................5-5
AX 15 MANUAL TRANSMISSION........21-33
AX 4/5 MANUAL TRANSMISSION.........21-1
AXLE (2WD), MODEL 30 AXLE AND
TUBE...............................2-22
AXLE, 8 1/4......................3-30,3-51
AXLE ALIGNMENT, REAR...............3-10
AXLE AND TUBE AXLE (2WD), MODEL
30 .................................2-22
AXLE ASSEMBLY REPLACEMENTÐXJ
VEHICLES, DRIVE; FRONT
SUSPENSION AND AXLE................2-23
AXLE ASSEMBLY REPLACEMENTÐXJ
VEHICLES, DRIVE; REAR SUSPENSION
AND AXLES......................3-14,3-31
AXLE ASSEMBLY REPLACEMENTÐYJ
VEHICLES, DRIVE; FRONT
SUSPENSION AND AXLE................2-24
AXLE ASSEMBLY REPLACEMENTÐYJ
VEHICLES, DRIVE; REAR SUSPENSION
AND AXLES..........................3-14
AXLE BUSHING REPLACEMENT......2-12,2-34
AXLE, FRONT DRIVE....................2-3
AXLE, MODEL 30.....................2-49
AXLE, MODEL 30 FRONT...............2-49
AXLE, MODEL 35.................3-13,3-51
AXLE NOISE/VIBRATION DIAGNOSIS;
FRONT SUSPENSION AND AXLE..........2-18
AXLE NOISE/VIBRATION DIAGNOSIS;
REAR SUSPENSION AND AXLES
..........3-9
AXLE SHAFT
.........................3-16
AXLE SHAFT, HUB BEARING
.............2-25
AXLE SHAFT OIL SEAL REPLACEMENT,
INNER
..............................2-35
AXLE SHAFT SEAL AND BEARING
........3-17
AXLE SHAFT, SEAL AND BEARING
SERVICE
............................3-32
AXLE SPECIFICATIONS; FRONT
SUSPENSION AND AXLE
................2-49
AXLE SPECIFICATIONS; REAR
SUSPENSION AND AXLES
...............3-51
AXLEÐYJ VEHICLES, VACUUM
DISCONNECT
.........................2-27
AXLES
...............................3-1
AXLES, FRONT AND REAR
..............0-24
AXLE/SHIFT MOTOR DIAGNOSIS
(CONT'D), DISCONNECT
................2-30
AXLE/SHIFT MOTOR DIAGNOSIS,
DISCONNECT
.........................2-29BACKLASH AND CONTACT PATTERN
ANALYSIS; FRONT SUSPENSION AND
AXLE...............................2-45
BACKLASH AND CONTACT PATTERN
ANALYSIS; REAR SUSPENSION AND
AXLES..............................3-27
BACK-UP LAMPS; REAR LIGHTING (XJ) . 8W-51-1
BACK-UP LAMPS; REAR LIGHTING
(XJ-RHD).........................8W-51-1
BACK-UP LAMPS; REAR LIGHTING (YJ) . 8W-51-1
BACK-UP/REAR TURN SIGNAL/TAIL
LAMP BULB REPLACEMENTÐXJ........8L-12
BACK-UP/REAR TURN SIGNAL/TAIL
LAMP BULB REPLACEMENTÐYJ........8L-28
BALANCE, TIRE AND WHEEL............22-6
BALL DIMENSIONS, AW-4 VALVE BODY
CHECK............................21-341
BALL STUD REPLACEMENTÐXJ,
LIFTGATE SUPPORT ROD..............23-63
BALL STUDS, STEERING KNUCKLE.......2-32
BAR, STABILIZER; FRONT SUSPENSION
AND AXLE.......................2-11,2-15
BAR, STABILIZER; REAR SUSPENSION
AND AXLES...........................3-5
BAR, TRACK; FRONT SUSPENSION AND
AXLE...........................2-11,2-15
BAR, TRACK; REAR SUSPENSION AND
AXLES...............................3-8
BARÐXJ, SOUND....................23-94
BARÐYJ, SPORT...................23-132
BARRIERÐXJ, CARGO...............23-101
BASE COAT/CLEAR COAT FINISH.........23-158
BATTERY; BATTERY/STARTER/
GENERATOR SERVICE..................8B-1
BATTERY; BATTERY/STARTING/
CHARGING SYSTEMS DIAGNOSTICS......8A-2
BATTERY; LUBRICATION AND
MAINTENANCE.......................0-20
BATTERY CHARGING...................8A-7
BATTERY CHARGING TIME TABLE........8A-8
BATTERY CLASSIFICATIONS AND
RATINGS...........................8A-23
BATTERY DIAGNOSIS..................8A-4
BATTERY FEED; FUEL/IGNITION (XJ) . . . 8W-30-1
BATTERY FEED; FUEL/IGNITION (YJ) . . . 8W-30-2
BATTERY FEED; FUEL/IGNITION
(XJ-RHD).........................8W-30-1
BATTERY RATINGS....................8A-3
BATTERY REMOVE/INSTALL.............8B-1
BATTERY SPECIFICATIONS; BATTERY/
STARTER/GENERATOR SERVICE..........8B-8
BATTERY SPECIFICATIONS; BATTERY/
STARTING/CHARGING SYSTEMS
DIAGNOSTICS.......................8A-23
BATTERY TRAYÐXJ..................23-14
BATTERY TRAYÐYJ.................23-110
BATTERY VOLTAGEÐPCM INPUT........14-21
B/C-PILLAR AND LIFTGATE PILLAR TRIM
COVERSÐXJ........................23-88
BEARING AND AXLE SHAFT, HUB.........2-25
BEARING, AXLE SHAFT SEAL............3-17
BEARING LUBRICANTS, CHASSIS
COMPONENT AND WHEEL..............0-28
BEARING NOISE, GEAR; FRONT
SUSPENSION AND AXLE................2-18
BEARING NOISE, GEAR; REAR
SUSPENSION AND AXLES................3-9
BEARING REPLACEMENT, PILOT..........6-12
BEARING REPLACEMENT, PITMAN
SHAFT SEALS.......................19-34
BEARING REPLACEMENT, RELEASE.......6-11
BEARING SERVICE, AXLE SHAFT, SEAL....3-32
BEARINGS, CRANKSHAFT MAIN......9-45,9-87
BEARINGS, FRONT WHEEL..............0-28
BELT, ACCESSORY DRIVE...............0-21
BELT DIAGNOSIS......................7-38
BELT INDICATOR WARNING LAMP, SEAT;
INSTRUMENT CLUSTER (XJ).........8W-40-2
BELT INDICATOR WARNING LAMP, SEAT;
INSTRUMENT CLUSTER (XJ-RHD).....8W-40-2
BELT SCHEMATICS....................7-38
BELT SERVICEÐEXCEPT RIGHT HAND
DRIVE
..............................7-40
BELT SERVICEÐXJ MODELS WITH
RIGHT HAND DRIVE
...................7-42
BELT SWITCH, DRIVER'S SEAT
......8U-1,8U-3
BELT TENSION, DRIVE
.................7-45
BELT TENSION SPECIFICATIONS
..........7-38
2 INDEXJ
Description Group-Page Description Group-Page Description Group-Page

PANEL (GOP)ÐXJ, GRILLE AND GRILLE
OPENING............................23-3
PANEL ILLUMINATION LAMPS,
INSTRUMENT; INTERIOR LIGHTING
(XJ).............................8W-44-1
PANEL ILLUMINATION LAMPS,
INSTRUMENT; INTERIOR LIGHTING
(XJ-RHD).........................8W-44-1
PANEL, INSTRUMENT.............8E-24,8E-1
PANEL INSULATOR PANELÐXJ, DASH....23-12
PANEL LAMP, ACCESSORY LAMP AND
HEATER CONTROL; INTERIOR
LIGHTING (YJ)....................8W-44-1
PANEL OUTLET VACUUM MOTOR
REPLACEMENT, HEATER/DEFROSTER/
INSTRUMENT.......................24-26
PANEL REMOVE/INSTALL, INSTRUMENT . . 8E-20
PANELÐXJ, DASH PANEL INSULATOR....23-12
PANELÐXJ, DOOR TRIM..............23-31
PANELÐXJ, FRONT INNER SCUFF
PLATE/COWL SIDE TRIM...............23-86
PANELÐXJ, LIFTGATE TRIM............23-59
PANELÐYJ, FULL-METAL DOOR TRIM . . . 23-137
PANELÐYJ, HOOD INSULATOR........23-107
PANELÐYJ, INSTRUMENT............23-151
PANELS AND SCUFF PLATESÐXJ,
INTERIOR TRIM......................23-84
PANELSÐXJ, QUARTER AND
WHEELHOUSE TRIM..................23-87
PARK GEAR OVERHAUL, GOVERNOR....21-127
PARK GEAR SERVICE, GOVERNOR......21-105
PARK INTERLOCK CABLE ADJUSTMENT . 21-195
PARK INTERLOCK CABLE ADJUSTMENT
(XJ)..............................21-101
PARK LOCK COMPONENT OVERHAUL,
ADAPTER/EXTENSION HOUSING
INSPECTION.......................21-127
PARK LOCK COMPONENT
REPLACEMENT.....................21-108
PARK NEUTRAL SWITCH..............14-63
PARK ROD AND PAWL SERVICE........21-190
PARKING BRAKE CABLE TENSIONER
ADJUSTMENT (XJ/YJ)..................5-69
PARKING BRAKE CABLE TENSIONER
REPLACEMENT (XJ)...................5-66
PARKING BRAKE FRONT CABLE
REPLACEMENT (YJ)...................5-67
PARKING BRAKE HANDLE COVERÐXJ....23-94
PARKING BRAKE LEVER INSTALLATION
(XJ WITH FULL CONSOLE)..............5-64
PARKING BRAKE LEVER INSTALLATION
(XJ WITH MINI CONSOLE)..............5-63
PARKING BRAKE LEVER INSTALLATION
(XJ WITHOUT CONSOLE)...............5-65
PARKING BRAKE LEVER REMOVAL (XJ
WITH FULL CONSOLE).................5-63
PARKING BRAKE LEVER REMOVAL (XJ
WITH MINI CONSOLE).................5-62
PARKING BRAKE LEVER REMOVAL (XJ
WITHOUT CONSOLE)...................5-64
PARKING BRAKE MALFUNCTIONS,
DIAGNOSING..........................5-8
PARKING BRAKE OPERATION............5-60
PARKING BRAKE PEDAL INSTALLATION
(YJ)................................5-66
PARKING BRAKE PEDAL REMOVAL (YJ) . . . 5-66
PARKING BRAKE REAR CABLE
REPLACEMENT (XJ)...................5-67
PARKING BRAKE REAR CABLE
REPLACEMENT (YJ)...................5-68
PARKING BRAKE SWITCH...............5-68
PARKING BRAKES.....................5-60
PARKING LAMPS; FRONT LIGHTING
(XJ).............................8W-50-1
PARKING LAMPS; FRONT LIGHTING
(XJ-RHD).........................8W-50-2
PARKING LAMPS; FRONT LIGHTING
(YJ).............................8W-50-1
PARK/NEUTRAL POSITION SWITCH;
FUEL/IGNITION (XJ)
................8W-30-4
PARK/NEUTRAL POSITION SWITCH;
FUEL/IGNITION (YJ)
................8W-30-4
PARK/NEUTRAL POSITION SWITCH;
TRANSMISSION AND TRANSFER CASE
. . 21-183
PARK/NEUTRAL POSITION SWITCH;
FUEL/IGNITION (XJ-RHD)
............8W-30-4
PARK/NEUTRAL POSITION SWITCH
SERVICE
..........................21-109PARK/NEUTRAL SWITCHÐPCM INPUT . . . 14-24
PARK/TURN SIGNAL LAMP BULB
REPLACEMENTÐXJ, FRONT.............8L-9
PARK/TURN SIGNAL LAMP BULB
REPLACEMENTÐYJ, FRONT............8L-25
PARTS INTERCHANGEABILITY,
TRANSMISSION CHANGES.............21-67
PARTS RECOMMENDATION,
LUBRICATION AND REPLACEMENT........0-2
PASSENGER'S POWER LOCK SWITCH.....8P-6
PASSENGER'S POWER WINDOW
SWITCH.............................8S-6
PATTERN ANALYSIS, BACKLASH AND
CONTACT; FRONT SUSPENSION AND
AXLE...............................2-45
PATTERN ANALYSIS, BACKLASH AND
CONTACT; REAR SUSPENSION AND
AXLES..............................3-27
PATTERN, SHIFT......................21-2
PATTERN, TRANSMISSION SHIFT........21-34
PATTERNS, TIRE WEAR................22-4
PAWL SERVICE, PARK ROD...........21-190
PCM SYSTEM SCHEMATICS............14-41
PEDAL, ACCELERATOR................14-17
PEDAL AND THROTTLE CABLE,
ACCELERATOR.................14-17,14-58
PEDAL BUSHINGS, CLUTCH AND BRAKE . . . 0-22
PEDAL INSTALLATION, BRAKE...........5-31
PEDAL INSTALLATION, CLUTCH..........6-15
PEDAL INSTALLATION (YJ), PARKING
BRAKE...............................5-66
PEDAL REMOVAL, BRAKE...............5-31
PEDAL REMOVAL, CLUTCH..............6-15
PEDAL REMOVAL (YJ), PARKING BRAKE . . . 5-66
PEDAL TRAVEL SENSOR, BRAKE;
ANTI-LOCK BRAKES (YJ)............8W-32-1
PEDALÐBRAKELIGHT SWITCH, POWER
BRAKE BOOSTERÐBRAKE..............5-22
PERFORMANCE, ENGINE.................9-2
PERFORMANCE TEMPERATURE AND
PRESSURE CHART, XJ................24-13
PERFORMANCE TEMPERATURE AND
PRESSURE CHART, YJ................24-13
PERFORMANCE TEST, REFRIGERANT
SERVICE...........................24-11
PERFORMANCE TESTS, AIR
CONDITIONING......................24-12
PILLAR TRIM COVERSÐXJ, B/C-PILLAR
AND LIFTGATE.......................23-88
PILOT BEARING REPLACEMENT..........6-12
PIN REPLACEMENT, CAMSHAFT......9-34,9-75
PIN REPLACEMENTÐXJ, DOOR
HINGE/HINGE.......................23-52
PINION GEAR ASSEMBLY/INSTALLATION . . . 2-42
PINION GEAR DEPTH INFORMATION;
FRONT SUSPENSION AND AXLE..........2-39
PINION GEAR DEPTH INFORMATION;
REAR SUSPENSION AND AXLES..........3-21
PINION GEAR DEPTH VARIANCE; FRONT
SUSPENSION AND AXLE................2-40
PINION GEAR DEPTH VARIANCE; REAR
SUSPENSION AND AXLES...........3-22,3-39
PINION MEASUREMENT AND ASSEMBLY . . . 3-22
PINION MEASUREMENT, DIFFERENTIAL....2-40
PINION REMOVAL/DISASSEMBLY; FRONT
SUSPENSION AND AXLE................2-36
PINION REMOVAL/DISASSEMBLY; REAR
SUSPENSION AND AXLES...............3-19
PINION SEAL REPLACEMENT; FRONT
SUSPENSION AND AXLE................2-25
PINION SEAL REPLACEMENT; REAR
SUSPENSION AND AXLES...............3-33
PINION SHAFT SEAL REPLACEMENT......3-15
PIPEÐXJ VEHICLES, EXHAUST..........11-3
PIPEÐYJ VEHICLES, EXHAUST..........11-4
PISTON AND TRANSMISSION CASE
OVERHAUL, FIRST-REVERSE BRAKE....21-247
PISTON AND WORM SHAFT
REPLACEMENT, RACK.................19-32
PISTON CLEARANCE, AW-4 BUSHING . . . 21-339
PISTON SPECIFICATIONS, AW-4
RETAINER.........................21-340
PISTONS AND CONNECTING RODS
. . . 9-39,9-81
PISTONS AND SPRINGS, ACCUMULATOR
. 21-189
PITMAN ARM
..................19-17,19-20
PITMAN SHAFT AND SIDE COVER
REPLACEMENT
......................19-28
PITMAN SHAFT SEAL REPLACEMENT
.....19-37PITMAN SHAFT SEALS AND BEARING
REPLACEMENT......................19-34
PITMAN SHAFT SEALSÐIN CAR
REPLACEMENT......................19-23
PIVOTS REMOVE/INSTALL, WINDSHIELD
WIPER LINKAGE.....................8K-17
PLANETARY GEAR AND CLUTCH
OVERHAUL, OVERDRIVE..............21-218
PLANETARY GEAR OVERHAUL, FRONT . . . 21-237
PLANETARY GEAR TRAIN OVERHAUL . . . 21-141
PLASTIC COMPONENT INSPECTION,
RUBBER............................0-20
PLASTIC HOSES/TUBING, RUBBER........0-26
PLASTIC INSERTÐXJ, REAR QUARTER
WINDOW GLASS/REAR QUARTER.......23-73
PLASTIGAGE, MEASURING WITH..........9-3
PLATE, FRONT SKID...................13-1
PLATE, FUEL TANK SKID...........13-15,13-3
PLATE LAMP HOUSINGÐXJ, LIFTGATE
LICENSE...........................23-65
PLATE LAMPÐXJ, LICENSE............8L-12
PLATE LAMPS, TAIL LAMPS AND
LICENSE.........................8W-51-1
PLATE LAMPS, TAIL LAMPS AND REAR
LICENSE; REAR LIGHTING (XJ).......8W-51-1
PLATE LAMPS, TAIL LAMPS AND REAR
LICENSE; REAR LIGHTING (XJ-RHD) . . . 8W-51-1
PLATE REPLACEMENT, SUPPORT.........5-58
PLATE SCREW ANCHOR AND BUMPERÐ
XJ, LIFTGATE LICENSE................23-65
PLATE SERVICE, CONVERTERÐPUMP
SEALÐDRIVE......................21-116
PLATE SPECIFICATIONS, 30RH/32RH
SNAP RING/THRUST WASHER/THRUST . . 21-335
PLATE THICKNESS, AW-4 CLUTCH DISC . 21-338
PLATE, TRANSFER CASE SKID......13-15,13-3
PLATE, VEHICLE CODE...............Intro.-4
PLATE, VEHICLE IDENTIFICATION
NUMBER (VIN).....................Intro.-4
PLATE/COWL SIDE TRIM PANELÐXJ,
FRONT INNER SCUFF.................23-86
PLATESÐXJ, INTERIOR TRIM PANELS
AND SCUFF.........................23-84
PLATESÐXJ, OUTER SCUFF............23-89
PLATESÐXJ, VEHICLE, LABELS........Intro.-2
PLATESÐYJ, VEHICLE, LABELS........Intro.-3
PLATFORMÐXJ, BUCKET SEAT.........23-82
PLUG ASSEMBLY REPLACEMENT,
ADJUSTER..........................19-29
PLUG CABLE RESISTANCE, SPARK......8D-14
PLUG, HOUSING END.................19-28
PLUG LOCATIONS, TRANSMISSION
SWITCH............................21-34
PLUG SECONDARY CABLES, SPARK.....8D-14,
8D-24
PLUGS, SPARK; IGNITION SYSTEMS....8D-12,
8D-23,8D-32
PLUGS, SPARK; LUBRICATION AND
MAINTENANCE.......................0-20
POLISHING, WET SANDING,BUFFING....23-158
POOR CONNECTIONS, INTERMITTENT;
WIRING DIAGRAMSÐGENERAL
INFORMATION (XJ)
...................8W-4
POSITION SENSOR, CAMSHAFT; FUEL
SYSTEM
............................14-60
POSITION SENSOR, CAMSHAFT;
FUEL/IGNITION (XJ)
................8W-30-3
POSITION SENSOR, CAMSHAFT;
FUEL/IGNITION (YJ)
................8W-30-3
POSITION SENSOR, CAMSHAFT;
IGNITION SYSTEMS
..............8D-17,8D-2
POSITION SENSOR, CAMSHAFT;
FUEL/IGNITION (XJ-RHD)
............8W-30-3
POSITION SENSOR, CRANKSHAFT; FUEL
SYSTEM
............................14-60
POSITION SENSOR, CRANKSHAFT;
FUEL/IGNITION (XJ)
................8W-30-3
POSITION SENSOR, CRANKSHAFT;
FUEL/IGNITION (YJ)
................8W-30-3
POSITION SENSOR, CRANKSHAFT;
IGNITION SYSTEMS
..............8D-17,8D-3
POSITION SENSOR, CRANKSHAFT;
FUEL/IGNITION (XJ-RHD)
............8W-30-3
POSITION SENSOR TEST, CAMSHAFT;
FUEL SYSTEM
.......................14-46
POSITION SENSOR TEST, CAMSHAFT;
IGNITION SYSTEMS
...................8D-6
20 INDEXJ
Description Group-Page Description Group-Page Description Group-Page