frame JEEP YJ 1995 Service And Manual PDF

(6) Install and tighten clutch housing-to-engine
bolts to 38 Nzm (28 ft. lbs.) torque.Be sure housing
is properly seated on engine before tightening
bolts.
(7) Lower transmission no more than 7.6 cm (3 in.)
for access to the shift tower.
(8) Reach up and around the transmission and in-
sert shift lever in shift tower. Press lever retainer
downward and turn it clockwise to lock it in place.
Then install lever dust boot on shift tower.
(9) Install and connect crankshaft position sensor.
(10) Align and install transfer case on transmis-
sion. Tighten transfer case attaching nuts to 35 Nzm
(26 ft. lbs.) torque.
(11) Connect transfer case vacuum and vent hoses.
(12) Install and connect transfer case shift linkage.
Check and adjust linkage if necessary.
(13) Secure wire harnesses to clips/tie straps on
transmission and transfer case.
(14) Connect backup light switch wires.
(15) Install clutch slave cylinder.
(16) Connect vehicle speed sensor wires.
(17) On XJ, install rear crossmember and attach
cushion and bracket. Tighten crossmember-to-frame
bolts to 41 Nzm (30 ft. lbs.) torque. Tighten transmis-
sion-to-rear cushion and bracket bolts/nuts to 45 Nzm
(33 ft. lbs.) torque.
(18) On YJ, install rear cushion and bracket and
skid plate. Tighten attaching bolts/nuts to indicated
torque (Fig. 1).
(19) Align and install front/rear propeller shafts.
Tighten shaft U-joint clamp bolts to 19 Nzm (170 in.
lbs.) torque.
(20) On XJ, install skid plate if removed. Tighten
bolts to 42 Nzm (31 ft. lbs.) torque. Tighten stud nuts
to 17 Nzm (150 in. lbs.) torque.
(21) Top off transmission and transfer lubricant
levels.
(22) Remove supports and lower vehicle.
TRANSMISSION DISASSEMBLY AND OVERHAUL
ADAPTER HOUSING REMOVAL
(1) Remove release bearing, release lever and re-
lease fork from clutch housing. Then remove clutch
housing from transmission.
(2) Remove backup light switch. Then remove
drain plug (Fig. 1) and drain transmission lubricant
into pan.
(3) Remove shift tower bolts and remove tower
from adapter or extension housing (Fig. 2).
(4) Remove gasket from shift tower (Fig. 3).
Fig. 1 Drain Plug And Backup Light Switch Location
Fig. 2 Shift Tower Removal/Installation
Fig. 3 Shift Tower Gasket Removal/Installation
JAX 15 MANUAL TRANSMISSION 21 - 37

30RH/32RH TRANSMISSION REMOVAL AND INSTALLATION
INDEX
page page
ConverterÐPump SealÐDrive Plate Service.... 116
Transmission and Converter Installation........ 117Transmission and Converter Removal......... 115
TRANSMISSION AND CONVERTER REMOVAL
(1) Remove fan shroud attaching bolts.
(2) Disconnect transmission fill tube at upper
bracket.
(3) Raise vehicle.
(4) Remove inspection cover from converter hous-
ing and remove skid plate for access, if necessary.
(5) Remove transmission fill tube and fill tube O-
ring.
(6) Remove starter motor.
(7) Mark propeller shafts and axle yokes for align-
ment reference.
(8) Disconnect propeller shafts at yokes. Secure
shafts to frame rails with wire.
(9) Disconnect exhaust pipes at exhaust manifolds,
if necessary.
(10) Drain transfer case lubricant, if transfer case
will also be serviced.
(11) Disconnect vehicle speed sensor wires.
(12) Disconnect transfer case shift linkage.
(13) Disconnect gearshift cable/linkage and throttle
valve cable at transmission levers.
(14) Disconnect transfer case vent hose. Then dis-
connect indicator switch wires on XJ, or vacuum
switch harness on YJ.
(15) Remove wire harness from clips on transfer
case.
(16) Remove transfer case attaching nuts and re-
move transfer case. Use transmission jack or helper
to support and remove transfer case.
(17) Disconnect park/neutral position switch wires.
(18) Disconnect and remove crankshaft position
sensor (Figs. 1 and 2). Retain sensor bolt (or bolts)
for reinstallation.
CAUTION: The crankshaft position sensor can be
damaged during transmission removal (or installa-
tion) if the sensor is still bolted to the engine block.
To avoid damage, remove the sensor before remov-
ing the transmission.
(19) Remove wire harnesses from clips/tie straps
on transmission.
(20) Remove converter housing access cover and
mark drive plate and converter for alignment refer-
ence.
(21) Remove bolts attaching converter to drive
plate.(22) Support engine with support stand.
(23) Support transmission with transmission jack.
Secure transmission to jack with safety chain.
Fig. 1 Crankshaft Position Sensor (2.5L)
Fig. 2 Crankshaft Position Sensor (4.0L YJ)
J30RH/32RH TRANSMISSION REMOVAL AND INSTALLATION 21 - 115

(3) Pull downward and remove the grille from ex-
haust port in the door opening panel.
INSTALLATION
(1) Position the slot located in the upper end of re-
placement grille at the exhaust port and insert edge
in the slot.
(2) Push inward and seat the grille in the exhaust
port.
(3) Install the screw to attach the grille to the door
opening panel.
EXTERIOR NAMEPLATESÐXJ
SERVICE INFORMATION
All of nameplates, with the exception of the JEEP
nameplate located on the grille are attached with ad-
hesive (Fig. 18).
GRILLE OPENING PANEL NAMEPLATE
REMOVAL
(1) Remove the grille opening panel (GOP) support
bracket.
(2) As applicable, remove the nut(s) from the let-
ter(s) that must be replaced.
(3) Remove the nameplate letter(s) from GOP.
INSTALLATION
(1) Clean the panel surface.
(2) Position the replacement letter(s) on the GOP.
(3) Install the nut(s) and tighten.
ADHESIVE-BACKED NAMEPLATES
REMOVAL/INSTALLATION
(1) Pry the nameplate from vehicle panel.
(2) Clean the panel surface.
(3) Position the replacement nameplate on the
panel push inward to seat it.
FUEL FILLER NOZZLE/TUBEÐXJ
REMOVAL
(1) Remove the fuel filler door from the quarter
panel (Fig. 19).
(2) For XJ vehicles, remove the fuel filler hose
splash shield from the quarter inner panel and frame
rail (Fig. 20).
(3) Remove the cap from the nozzle (Fig. 21).
(3) Loosen the clamps and separate the hoses from
the tubes.
(4) Remove the screws that attach the nozzle to
the housing.
(5) Remove the nozzle/tube from the fuel filler
housing (Fig. 22).
INSTALLATION
(1) Insert the fuel filler nozzle/tube into the hous-
ing.
(2) Install the screws to attach the nozzle/tube to
the housing. Tighten screws to 2 Nzm (20 in-lbs)
torque.
Fig. 18 XJ Exterior Nameplates
Fig. 19 Fuel Filler DoorÐTypical
Fig. 20 Fuel Filler Hose Splash ShieldÐXJ Vehicles
23 - 26 EXTERIOR COMPONENTSÐXJJ

(3) Attach the hoses to the tubes with clamps.
Tighten the clamp screws to 4 Nzm (35 in-lbs) torque.
(4) Install the cap on nozzle.
(5) Install the fuel filler hose splash shield on the
quarter inner panel and frame rail.
(6) Install the fuel filler door on the quarter panel.
FUEL FILLER DOOR BUMPERSÐXJ
REPLACEMENT
(1) Grasp the bumper (Fig. 23) with pliers and pull
outward to remove it from the hole.
²It may be necessary to remove the door (Fig. 24) to
replace the door-stop bumper.
(2) Insert bumpers in the holes and force them in-
ward until they are seated in the holes.
EXTERNAL MIRRORSÐXJ
SERVICE INFORMATION
Service procedures for all external rear view mir-
rors are below.
REMOTE AND POWER/MANUAL MIRRORS
REMOVAL
(1) Remove the door trim panel.
(2) Remove the mirror inside trim cover screw (Fig.
1).
Fig. 21 Fuel Filler Nozzle/TubeÐXJ Vehicles
Fig. 22 Fuel Filler Nozzle/Tube Removal/
InstallationÐXJ Vehicles
Fig. 23 Fuel Filler Door Bumpers
Fig. 24 Fuel Filler Door-Stop Bumper
Fig. 1 Remote MirrorsÐPower/Manual
JEXTERIOR COMPONENTSÐXJ 23 - 27

14). Be careful not to bend the hinge when driving
the hinge pin, support may be required under the
hinge.
(8) Adjust/align latch striker and latch as neces-
sary.(9) Install the door restraint (check) retaining pin
with a punch.
FRONT DOOR SPACER BLOCKSÐTWO-DOOR
VEHICLES
REMOVAL
(1) Upper spacer block: drill-out the rivet heads
and remove them from the reinforcement plate (Fig.
1).
(2) Lower spacer block: remove the screws from the
door face (Fig. 2).
(3) As applicable, remove the spacer block from the
door window frame or door face.
INSTALLATION
(1) As applicable, position the spacer block on the
door window frame or door face.
(2) Upper spacer block: Install the replacement riv-
ets in the spacer block and reinforcement plate.
Fig 11 Install Bushing In Hinge
Fig. 12 Begin To Roll Bushing Material Outward
Fig. 13 Forming A Head On The Bushing
Fig. 14 Installing The Hinge Pin
Fig. 1 Front Door Upper Spacer BlockÐTwo-Door
Vehicles
JDOORSÐXJ 23 - 53

The stop lamp and turn signal plug-in relays are
located behind left quarter trim panel (Fig. 3).
HITCH REMOVALÐXJ VEHICLES
An XJ class III, weight-distributing/equalizer type
hitch (Fig. 4)is comprised of:
²Towing tube with a ball mount receptacle.
²Various reinforcement/support brackets that are
attached to the vehicle frame sills and rear cross-
member with bolts.(1) If necessary, remove the trailer tow wire har-
ness connector from the hitch (Fig. 5).
(2) Support the hitch.
(3) Remove the bolts that attach the towing tube to
the frame sills and reinforcement bracket. If
equipped, remove the fuel tank skid plate.
The reinforcement brackets are held on the
frame sills with two blind rivets.
(4) Remove the bolts from the plate bracket and
rear crossmember and lower the support and hitch.
Fig. 4 Equalizer Type HitchÐXJ Vehicles
Fig. 2 Class III Trailer Tow Wire Harness and
ConnectorsFig. 3 Class III Trailer Tow Wire Harness Plug-In
Relays
23 - 78 TRAILER HITCHJ

INSTALLATIONÐXJ VEHICLES
(1) Install frame reinforcement brackets, if re-
moved. Slide the brackets through the vehicle rear
sill openings and hold in position on the frame sills
with blind rivets (Fig. 6).(2) Place hitch on a lifting device. Raise, position
hitch at the proper location for installation on vehicle
and support it.
(3) If equipped, position fuel tank skid plate on ve-
hicle frame sills.
(4) Loosely install the bolts to attach the towing
tube (and the skid plate) to frame sills and reinforce-
ment brackets.
(5) Position the plate bracket and install the at-
taching bolts through the vehicle rear crossmember.
(6) Tighten all bolts/nuts to the specified torque:
²Towing tube-to-reinforcement bracket bolt, 50 Nzm
(37 ft. lbs.).
²Plate bracket-to-rear crossmember nut, 52 Nzm (40
ft. lbs.).
(7) Remove the lift/support and, if removed, attach
the trailer wire harness connector to the hitch.
Fig. 6 Reinforcement Bracket and Hitch Installation
Fig. 5 Trailer Tow Wire Harness Connector
JTRAILER HITCH 23 - 79

INTERIOR COMPONENTS
INDEX
page page
Assist HandleÐXJ........................ 89
B/C-Pillar and Liftgate Pillar Trim CoversÐXJ.... 88
Bucket Seat Cushion and CoverÐXJ........... 81
Bucket Seat PlatformÐXJ................... 82
Bucket Seatback Cover and FrameÐXJ........ 81
Cargo BarrierÐXJ........................ 101
Cargo LampÐXJ......................... 94
Carpets and Floor MatsÐXJ................. 99
Dome LampÐXJ......................... 93
Front Bucket SeatsÐXJ.................... 81
Front Carpet/MatÐXJ...................... 99
Front Inner Scuff Plate/Cowl Side Trim PanelÐXJ . 86
Front Shoulder Belt/BuckleÐXJ............... 90
Full Floor ConsoleÐXJ..................... 95
HeadlinerÐXJ............................ 92
I/P Ash Receiver Tray LampÐXJ.............. 80
Instrument Cluster BezelÐXJ................ 80
Interior Trim Panels and Scuff PlatesÐXJ....... 84
Jack StorageÐXJ......................... 97
Keyless Entry ReceiverÐXJ................. 93Mini-Console with Floor ShiftÐXJ............. 94
Mini-Floor ConsoleÐXJ..................... 94
Outer Scuff PlatesÐXJ..................... 89
Overhead ConsoleÐXJ..................... 93
Parking Brake Handle CoverÐXJ............. 94
Quarter and Wheelhouse Trim PanelsÐXJ...... 87
Quarter Trim Panel ExtensionÐXJ............. 87
Rear Carpet/MatÐXJ..................... 100
Rear Seat Cushion CoverÐXJ............... 82
Rear Seat CushionÐXJ.................... 82
Rear Seatback CoverÐXJ................... 84
Rear Seatback Latch Striker and BumperÐXJ.... 84
Rear SeatbackÐXJ........................ 83
Rear Shoulder/Lap Belt/BuckleÐXJ............ 91
Sound BarÐXJ........................... 94
Spare Tire/Wheel Holddown and Floor
BracketsÐXJ........................... 98
SunvisorsÐXJ........................... 93
Windshield Side MoldingÐXJ................ 86
INSTRUMENT CLUSTER BEZELÐXJ
REMOVAL
(1) Remove the bezel retaining screws (Fig. 1).
(2) Separate the bezel from the U-clips and remove
it from the upper section of the instrument panel.
(3) If necessary, remove or install rocker switch
cover plates.
INSTALLATION
(1) Position the bezel on the upper instrument
panel and engage it with the U-clips.
(2) Install the bezel retaining screws. Tighten thescrews with 1 Nzm (11 in-lbs) torque.
For service procedures regarding individual I/P
components refer to Group 8, Electrical.
I/P ASH RECEIVER TRAY LAMPÐXJ
REMOVAL
(1) Remove the ash receiver tray from instrument
panel (Fig. 2).
(2) Remove the lamp retaining screw from the ash
receiver tray cavity (Fig. 3).
(3) Disconnect the lamp wire harness connector
and remove the lamp from the instrument panel.
Fig. 1 Instrument Bezel Removal/Installation
Fig. 2 Ash Receiver Tray
23 - 80 INTERIOR COMPONENTSÐXJJ

INSTALLATION
(1) Position the lamp under the instrument panel
and connect the lamp wire harness connector.
(2) Install the lamp retaining screw in the ash re-
ceiver tray cavity.
(3) Install the ash receiver tray in the instrument
panel.
FRONT BUCKET SEATSÐXJ
REMOVAL
Bucket seat platforms are attached to the floor
panel with bolts (Fig. 1).
(1) Remove seat frame bolts.
(2) For power seats, disconnect wire harness con-
nector.
(3) Separate seat from floor panel.
INSTALLATION
(1) Position seat on floor panel.
(2) Install seat frame bolts. Tighten to 32 Nzm (24
ft-lbs) torque.(3) For power seats, connect wire harness connec-
tor.
BUCKET SEAT CUSHION AND COVERÐXJ
REMOVAL
(1) Remove the seat from vehicle (Fig. 1). If neces-
sary, refer to removal procedure.
(2) Remove seat trim cover.
(3) Remove wire support rod and rear carpet seat
track cover, and flap retainer.
(4) For power seats, remove control housing from
seat cushion.
(5) Unclip skirt from seat cushion and seat frame.
(6) Remove seat cushion cover retaining screws
and wire rods from cushion cover. Remove cover from
cushion frame.
INSTALLATION
(1) Install seat cushion cover on cushion frame. In-
stall wire rods and retaining screws. Tighten screws
to2Nzm (13 in-lbs) torque.
(2) Install cushion and retaining screws on seat
frame.
(3) Clip skirt onto seat cushion and seat frame.
(4) For power seats, install control housing on seat
cushion. Tighten screws to 2 Nzm (13 in-lbs) torque.
(5) Install rear carpet seat track cover and support
rod and flap retainer.
(6) Install seat trim cover and screws onto seat
platform.
(7) Install seat in vehicle (Fig. 1). If necessary, re-
fer to removal procedure.
BUCKET SEATBACK COVER AND FRAMEÐXJ
REMOVAL
(1) Remove seat from vehicle. If necessary, refer to
removal procedure.
(2) Remove seat cushion from frame. If necessary,
refer to removal procedure.
(3) If equipped, remove headrest. Twist knob under
headrest and pull up and out of cylinders in seat-
back.
(4) Remove headrest latch release lever bezel from
seatback.
(5) Squeeze plastic retainers together. Detach
lower flap from front of cover.
(6) Remove cover retainer clips and remove cover
from seatback.
(7) For power seats, remove retaining screws and
remove the seat control from seat track/platform.
(8) Remove retaining screws and nuts. Remove
seat frame from seat track/platform.
INSTALLATION
(1) Position seat frame on seat track/platform. In-
stall retaining screws and nuts.
Fig. 3 Ash Receiver Tray Lamp
Fig. 1 Bucket Seat
JINTERIOR COMPONENTSÐXJ 23 - 81

(2) For power seats, position seat control on seat
track/platform. Install retaining screws. Tighten
screws securely.
(3) Position cover on seatback. Install cover re-
tainer clips.
(4) Attach cover bottom elastic band or attach Vel-
cro flap to front of cover.
(5) Install seatback insert.
(6) Install headrest latch release lever bezel.
(7) Install headrest by pushing it down into seat-
back cylinders.
(8) Install cushion on frame. If necessary, refer to
installation procedure.
(9) Install seat in the vehicle. If necessary, refer to
the installation procedure.
(10) For power seats, test seat operation.
BUCKET SEAT PLATFORMÐXJ
REPLACEMENT
Bucket seat platforms are not repairable. If the
seat platform is damaged, replace platform as a unit.
REAR SEAT CUSHIONÐXJ
REMOVAL
(1) Disengage the seat cushion at the rear by pull-
ing upward on the release strap (Fig. 1).
(2) Tilt the seat cushion forward.
(3) Disengage the seat cushion latch with the re-
lease lever (Fig. 2 and 3). Separate the right side
latch and then the left side seat bracket from the
floor anchor bolts, and remove the cushion from the
vehicle.
INSTALLATION
(1) Position the seat cushion in the vehicle (Fig. 3).
(2) Insert the left pivot in the anchor grommet.
(3) Force the right side latch onto the anchor bolt
and pivot the seat cushion to the horizontal position.
(4) Lock the seat cushion in-place by pressing
firmly on the center of the cushion until the latch en-
gages.
REAR SEAT CUSHION COVERÐXJ
REMOVAL
(1) Remove the seat cushion from the vehicle.
(2) Remove the cover side, front and rear retaining
clips from the wire retainers with an appropriate re-
moval tool (Fig. 4).
(3) Remove the serrated retainers from the front
ends of the cover with a trim panel removal tool (Fig.
5).
(4) Remove the seat cover from the cushion.Fig. 1 Seat Cushion Disengagement At Rear
Fig. 2 Seat Cushion Disengagement At Front
Fig. 3 Rear Seat Cushion Removal/Installation
23 - 82 INTERIOR COMPONENTSÐXJJ