4 wheel drive JEEP YJ 1995 Service And Repair Manual

CLASSIFICATION OF LUBRICANTS
Lubricating fluids and chassis lubricants are clas-
sified according to standards recommended by the:
²Society of Automotive Engineers (SAE)
²American Petroleum Institute (API)
²National Lubricating Grease Institute (NLGI)
ENGINE OIL
API CERTIFICATION MARK
For maximum engine protection during all driving
conditions, install an engine oil that contains the API
Certification Mark (Fig. 2). The API Certification
Mark indicates that the oil is certified to meet the
most critical requirements established by the manu-
facturer.
Conformance to API specifications is determined by
tests that measure the ability of an oil to control:
²Engine wear.
²Bearing corrosion.
²Sludge.
²Varnish.
²Oil thickening.
²Rust.
²Piston deposits.
SAE VISCOSITY GRADE
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. SAE 30 specifies a single viscos-
ity engine oil. Engine oils also have multiple
viscosities. These are specified with a dual SAE vis-
cosity grade which indicates the cold-to-hot tempera-
ture viscosity range.
API SERVICE GRADE CERTIFIED
The API Service Grade specifies the type of perfor-
mance the engine oil is intended to provide. The API
Service Grade specifications also apply to energy con-
serving engine oils.
Use an engine oil that is API Service Grade Certi-
fied or an oil that conforms to the API Service Grade
SH or SH/CD. MOPAR provides engine oils that con-
form to all of these service grades.
GEAR LUBRICANTS
A dual grade is also used to specify the viscosity of
multi-purpose gear lubricants.
The API grade designation identifies gear lubri-
cants in terms of recommended usage.
CHASSIS COMPONENT AND WHEEL BEARING
LUBRICANTS
The chassis and wheel bearing lubricants that are
recommended are identified by the NLGI Certifica-
tion Symbol. The symbol contains a coded designa-
tion. This identifies the usage and quality of the
lubricant.
The letter G within the symbol designates wheel
bearing lubricant. The letter L designates chassis lu-
bricant. When the letters are combined, the lubricant
can be used for dual applications. Use only lubricants
that display the NLGI Certification Symbol (Fig. 3).
LUBRICATION AND REPLACEMENT PARTS
RECOMMENDATION
Jeep vehicles are engineered to provide many years
of dependable operation. However, lubrication service
and maintenance are required for each vehicle. When
necessary, MOPARtbrand lubricants and genuine re-
placement parts are highly recommended. Each MO-
PAR brand lubricant and replacement part is
designed and to provide dependability and long ser-
vice life.
COMPONENTS REQUIRING NO LUBRICATION
There are many components that should not be lu-
bricated. The components that should not be lubri-
cated are:
²Air pumps.
²Generator bearings.
²Distributors.
²Drive belts.
²Drive belt idler pulleys.
²Rubber bushings.
²Starter motor bearings.
²Suspension strut bearings.
²Throttle control cables.
²Throttle linkage ball joints.
²Water pump bearings.
Fig. 2 The API Engine Oil Certification Mark
Fig. 3 NLGI Lubricant Container Certification/
Identification Symbol
0 - 2 LUBRICATION AND MAINTENANCEJ

MAINTENANCE SCHEDULES
INTRODUCTION
There are two maintenance schedules that show
proper service intervals for Jeep Cherokee and Jeep
Wrangler vehicles. Use the schedule that best de-
scribes the conditions the vehicle is operated under.
When mileage and time is listed, follow the interval
that occurs first.
ScheduleÐAlists all the scheduled maintenance
to be performed under normal operating conditions.
ScheduleÐBis a schedule for vehicles that are
usually operated under one or more of the following
conditions.
²Frequent short trip driving less than 5 miles (8
km).
²Frequent driving in dusty conditions.
²Trailer towing or heavy load hauling.
²Frequent long periods of engine idling.
²Sustained high speed operation.
²Desert operation.
²Frequent starting and stopping.
²Cold climate operation.
²Off road driving.
²Commercial service.
²Snow plow operation.
²More than half of vehicle operation occurs in
heavy city traffic during hot weather (above 90É F).
AT EACH STOP FOR GASOLINE
²Check engine oil level and add as required.
²Check windshield washer solvent and add as re-
quired.
ONCE A MONTH
²Check tire pressure and look for unusual tire wear
or damage.
²Check fluid levels of coolant reservoir, brake mas-
ter cylinder, power steering and transmission. Add
fluid as required.
²Check all lights and other electrical items for cor-
rect operation.
²Inspect battery and clean and tighten terminals as
required.
²Check rubber seals on each side of the radiator for
proper fit.
AT EACH OIL CHANGE
²Inspect exhaust system.
²Inspect brake hoses.
²Rotate the tires at each oil change interval shown
on ScheduleÐA: (7,500 Miles) or every other interval
shown on ScheduleÐB: (6,000 Miles).
²Check engine coolant level, hoses, and clamps.
²Lubricate 4x4 steering linkage.
²Lubricate propeller shaft universal joints and slip
spline, if equipped.After completion of off-road (4WD) operation, the
underside of the vehicle should be thoroughly in-
spected. Examine threaded fasteners for looseness.
HARSH SURFACE ENVIRONMENTS
After vehicle operation in a harsh surface environ-
ment, the following components should be inspected
and cleaned as soon as possible:
²Brake drums.
²Brake linings.
²Front wheel bearings (2WD vehicles only).
²Axle coupling joints.
This will prevent wear and/or unpredictable brake
action.
EMISSION CONTROL SYSTEM MAINTENANCE
The schedule emission maintenance listed inbold
typeon the following schedules, must be done at the
mileage specified to assure the continued proper
functioning of the emission control system. These,
and all other maintenance services included in this
manual, should be done to provide the best vehicle
performance and reliability. More frequent mainte-
nance may be needed for vehicles in severe operating
conditions such as dusty areas and very short trip
driving.
SCHEDULEÐA
7,500 MILES (12 000 KM) OR AT 6 MONTHS
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
15,000 MILES (24 000 KM) OR AT 12 MONTHS
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage.
22,500 MILES (36 000 KM) OR AT 18 MONTHS
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
²Inspect brake linings.
30,000 MILES (48 000 KM) OR AT 24 MONTHS
²Replace air cleaner element.
²Replace spark plugs.
²Adjust belt tension on non-automatic tensioning
drive belts.
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage.
²Drain and refill automatic transmission.
²Drain and refill transfer case.
0 - 4 LUBRICATION AND MAINTENANCEJ

SCHEDULEÐB
3,000 MILES (4 800KM)
²Change engine oil.
²Replace engine oil filter.
6,000 MILES (9 600KM)
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
9,000 MILES (14 400KM)
²Change engine oil.
²Replace engine oil filter.
12,000 MILES (19 200KM)
²Change engine oil.
²Replace engine oil filter.
²Drain and refill automatic transmission.
²Change front and rear axle fluid.*
²Lubricate steering linkage (4x4).
²Inspect brake linings.
15,000 MILES (24 000KM)
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x2).
²Inspect air cleaner element, replace as necessary.
18,000 MILES (29 000KM)
²Change engine oil.
²Replace engine oil filter.
²Drain and refill Manual transmission fluid.
²Lubricate steering linkage (4x4).
21,000 MILES (34 000KM)
²Change engine oil.
²Replace engine oil filter.
24,000 MILES (38 000KM)
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
²Drain and refill automatic transmission.
²Change front and rear axle fluid.*
²Inspect brake linings.
²Inspect front wheel bearings, Clean and repack if
required (4x2).
27,000 MILES (43 000KM)
²Change engine oil.
²Replace engine oil filter.
30,000 MILES (48 000KM)
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage joints.
²Replace spark plugs.
²Replace air cleaner element.²Adjust drive belts.
²Drain and refill transfer case fluid.
33,000 MILES (53 000KM)
²Change engine oil.
²Replace engine oil filter.
36,000 MILES (58 000KM)
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
²Drain and refill automatic transmission.
²Drain and refill manual transmission fluid.
²Change front and rear axle fluid.*
²Inspect brake linings.
39,000 MILES (62 000KM)
²Change engine oil.
²Replace engine oil filter.
42,000 MILES (67 000KM)
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
45,000 MILES (72 000KM)
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x2).
²Inspect air cleaner element, replace as necessary.
48,000 MILES (77 000KM)
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
²Drain and refill automatic transmission.
²Change front and rear axle fluid.*
²Inspect brake linings.
51,000 MILES (82 000KM)
²Change engine oil.
²Replace engine oil filter.
²Flush and replace engine coolant.
54,000 MILES (86 400KM)
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
²Drain and refill Manual transmission fluid.
57,000 MILES (91 000KM)
²Change engine oil.
²Replace engine oil filter.
60,000 MILES (96 000KM)
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage joints.
²Replace spark plugs.
0 - 6 LUBRICATION AND MAINTENANCEJ

JUMP STARTING, TOWING AND HOISTING
INDEX
page page
Four-Wheel-Drive Vehicle Towing............. 12
Ground Clearance and Ramp Angle............ 11
Hoisting Recommendations.................. 10
Jump Starting Procedure..................... 9Towing Recommendations................... 10
Towing When Keys Are Not Available.......... 13
Two-Wheel-Drive Vehicle TowingÐXJ.......... 11
JUMP STARTING PROCEDURE
WARNING: DO NOT ATTEMPT TO PUSH OR TOW A
VEHICLE TO START THE ENGINE. UNBURNED
FUEL COULD ENTER THE EXHAUST CATALYTIC
CONVERTER AND IGNITE AFTER THE ENGINE IS
STARTED. THIS COULD CAUSE THE CONVERTER
TO OVERHEAT AND RUPTURE.
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS.
DO NOT JUMP START A FROZEN BATTERY, PER-
SONAL INJURY CAN RESULT.
DO NOT JUMP START WHEN MAINTENANCE
FREE BATTERY INDICATOR DOT IS YELLOW OR
BRIGHT COLOR.
DO NOT JUMP START A VEHICLE WHEN THE
BATTERY FLUID IS BELOW THE TOP OF LEAD
PLATES.
DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
DO NOT USE OPEN FLAME NEAR BATTERY.
REMOVE METALLIC JEWELRY WORN ON HANDS
OR WRISTS TO AVOID INJURY BY ACCIDENTAL
ARCING OF BATTERY CURRENT.
WHEN USING A HIGH OUTPUT BOOSTING DE-
VICE, DO NOT ALLOW BATTERY VOLTAGE TO EX-
CEED 16 VOLTS. REFER TO INSTRUCTIONS
PROVIDED WITH DEVICE BEING USED.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually in-
spect engine compartment for:
²Battery cable clamp condition, clean if necessary.
²Frozen battery.
²Yellow or bright color test indicator, if equipped.
²Low battery fluid level.
²Generator drive belt condition and tension.²Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, turn off all accessories, place gear selector in
park or neutral, set park brake and operate engine at
1200 rpm.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result. Re-
view all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible (Fig. 1).
Fig. 1 Jumper Cable ConnectionsÐTypical
JLUBRICATION AND MAINTENANCE 0 - 9

CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(6) Allow battery in disabled vehicle to charge to at
least 12.4 volts (75%charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
²When using a Booster vehicle, disconnect BLACK
cable clamp from battery negative terminal. Discon-
nect RED cable clamp from battery positive terminal.
²Disconnect RED cable clamp from battery positive
terminal on disabled vehicle.
PORTABLE STARTING UNIT
There are many types of portable starting units
available for starting engines. Follow the manufac-
turer's instructions and observe the listed precau-
tions when involved in any engine starting
procedure.
HOISTING RECOMMENDATIONS
Refer to the Owner's Manual for emergency vehicle
lifting procedures.
FLOOR JACK
When properly positioned, a floor jack can be used
to lift a Jeep vehicle (Fig. 2 and 3). Support the ve-
hicle in the raised position with jack stands at the
front and rear ends of the frame rails.
CAUTION: Do not attempt to lift a Jeep vehicle with
a floor jack positioned under:
²An axle tube.
²A body side sill.
²A steering linkage component.
²A drive shaft.
²The engine or transmission oil pan.
²The fuel tank.
²A front suspension arm.
Use the correct sub-frame rail or frame rail
lifting locations only (Fig. 2 and 3).
HOIST
A vehicle can be lifted with:
²A single-post, frame-contact hoist.
²A twin-post, chassis hoist.
²A ramp-type, drive-on hoist.
When a frame-contact type hoist is used, ver-
ify that the lifting pads are positioned properly
(Fig. 2 and 3).WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING DE-
VICE WHEN THESE CONDITIONS EXIST.
TOWING RECOMMENDATIONS
A vehicle equipped with SAE approved sling-type
towing equipment can be used to tow all Jeep vehi-
cles. When towing a 4WD vehicle using a wheel-lift
towing device, use a tow dolly under the opposite end
of the vehicle. A vehicle with flat-bed device can also
be used to transport a disabled vehicle (Fig. 4).
A wooden crossbeam may be required for proper
connection when using the sling-type, front-end tow-
ing method.
SAFETY PRECAUTIONS
²Secure loose and protruding parts.
²Always use a safety chain system that is indepen-
dent of the lifting and towing equipment.
²Do not allow towing equipment to contact the dis-
abled vehicle's fuel tank.
²Do not allow anyone under the disabled vehicle
while it is lifted by the towing device.
Fig. 2 Vehicle Lifting LocationsÐTypical
0 - 10 LUBRICATION AND MAINTENANCEJ

²Do not allow passengers to ride in a vehicle being
towed.
²Always observe state and local laws regarding tow-
ing regulations.²Do not tow a vehicle in a manner that could jeop-
ardize the safety of the operator, pedestrians or other
motorists.
²Do not attach tow chains, T-hooks, J-hooks, or a
tow sling to a bumper, steering linkage, drive shafts
or a non-reinforced frame hole.
GROUND CLEARANCE AND RAMP ANGLE
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums.
A towed vehicle should be raised until lifted wheels
are a minimum 100 mm (4 in) from the ground. Be
sure there is adequate ground clearance at the oppo-
site end of the vehicle, especially when towing over
rough terrain or steep rises in the road. If necessary,
remove the wheels from the lifted end of the vehicle
and lower the vehicle closer to the ground, to in-
crease the ground clearance at the opposite end of
the vehicle. Install lug nuts on wheel attaching studs
to retain brake drums.
FLAT-BED TOWING RAMP ANGLE
If a vehicle with flat-bed towing equipment is used,
the approach ramp angle should not exceed 15 de-
grees.
TWO-WHEEL-DRIVE VEHICLE TOWINGÐXJ
Chrysler Corporation recommends that a vehicle be
towed with the rear end lifted, whenever possible.
TOWING-REAR END LIFTED (SLING-TYPE)
CAUTION: Do not use steering column lock to se-
cure steering wheel during towing operation.
2WD XJ vehicles can be towed with the front
wheels on the surface for extended distances at
speeds not exceeding 48 km/h (30 mph).
(1) Attach J-hooks around the axle shaft tube out-
board of the shock absorber.
(2) Place the sling crossbar under and forward of
the bumper.
(3) Attach safety chains around the frame rails.
(4) Turn the ignition switch to the OFF position to
unlock the steering wheel.
(5) Secure steering wheel in the straight ahead po-
sition with a clamp device designed for towing.
(6) Verify that steering components are in good
condition.
(7) Shift the transmission to NEUTRAL.
Fig. 3 Correct Vehicle Lifting LocationsÐTypical
Fig. 4 Tow Vehicles With Approved Equipment.
JLUBRICATION AND MAINTENANCE 0 - 11

TOWING-FRONT END LIFTED (SLING-TYPE)
CAUTION: Many vehicles are equipped with air
dams, spoilers, and/or ground effect panels. To
avoid component damage, a wheel-lift towing vehi-
cle or a flat-bed hauling vehicle is recommended.
If a 2WD XJ vehicle cannot be towed with the rear
wheels lifted, it can be towed with the front wheels
lifted.
(1) Attach a J-hook to the disabled vehicle at the
left side of the axle.
(2) Position the sling crossbar close to the J-hook
and below the front bumper.
(3) Secure a chain to the right side of vehicle by
placing it over the axle shaft tube and attaching it to
a structural member (Fig. 5).
(4) Attach the safety chains to the vehicle.
(5) Turn the ignition switch to the OFF position to
unlock the steering wheel.
2WD-AUTOMATIC TRANSMISSION
Provided the transmission is operable, tow only in
NEUTRALat speeds not to exceed 30 mph (50
km/h) and distances less than 15 miles (25km/h).
If the vehicle is to be towed more than 15 miles,
the propeller shaft should be disconnected or place
tow dollies under rear wheels.
2WD-MANUAL TRANSMISSION
To reduce the possible damage of transmission com-
ponents, the propeller shaft must be removed or
place tow dollies under the rear wheels before tow-
ing. Refer to Propeller Shafts, Group 16 for proper
removal procedure.
FOUR-WHEEL-DRIVE VEHICLE TOWING
Chrysler Corporation recommends that a vehicle be
transported on a flat-bed device. A Wheel-lift or
Sling-type device can be used provided all the wheels
are lifted off the ground using tow dollies.
TOWING-REAR END LIFTED (SLING-TYPE)
4WD XJ VEHICLES
(1) Raise the front of the vehicle off the ground
and install tow dollies under front wheels.
(2) Attach J-hooks around the rear axle shaft tube
outboard of the shock absorber.
(3) Place the sling crossbar under and forward of
the bumper.
(4) Attach safety chains around the frame rails.
(5) Turn the ignition switch to the OFF position to
unlock the steering wheel.
(6) Secure steering wheel in the straight ahead po-
sition with a clamp device designed for towing.
(7) Shift the transfer case to NEUTRAL.
4WD YJ VEHICLES
Use Wheel-Lift equipment and Tow Dollies
when towing from the rear end of the vehicle.
TOWING-FRONT END LIFTED (SLING-TYPE)
4WD XJ VEHICLES
(1) Raise the rear of the vehicle off the ground and
install tow dollies under rear wheels.
(2) Attach a J-hook to the disabled vehicle at the
left side of front the axle.
(3) Position the sling crossbar close to the J-hook
and below the front bumper (Fig. 6).
(4) Secure a chain to the right side of vehicle by
placing it over the axle shaft tube and attaching it to
a structural member
(4) Attach the safety chains to the vehicle.
(5) Turn the ignition switch to the OFF position to
unlock the steering wheel.
(6) Shift transfer case to NEUTRAL.
Fig. 5 Sling-Type, Front-End Towing (XJ Rear View)
Fig. 6 Sling-Type, Front-End Towing (XJ Front View)
0 - 12 LUBRICATION AND MAINTENANCEJ

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

(5) Inspect the reservoir rubber diaphragm seal for
cracks, cuts and distortion.
(6) Inspect the brake fluid tubing fittings and the
master cylinder housing for indications of fluid leak-
age. Repair as necessary.
(7) Install the brake fluid reservoir cover.
ANTI-LOCK BRAKE SYSTEMÐXJ VEHICLES
The anti-lock brake system fluid reservoir for XJ
Vehicles is located in the engine compartment at the
left side of the dash panel.
(1) Turn the ignition switch ON and allow the
pump motor to operate until it automatically de-en-
ergizes.
(2) Clean the cover before removing it.
CAUTION: Over-filling could cause fluid overflow
and possible reservoir damage when the pump mo-
tor energizes.
(3) The brake fluid level should be no lower than
the ADD indicator on the side of the reservoir (Fig.
8). If not, add brake fluid as necessary. Raise the
fluid level to the FULL indicator only. Do not over-fill
the reservoir.
(4) Turn the ignition switch OFF.
BRAKE SYSTEM INSPECTION
A brake system inspection should be included with
all brake service procedures, and also each time the
vehicle is lubricated.
(1) Inspect the brake pads and linings for excessive
wear, cracks, charred surfaces and broken rivets.
(2) Inspect brake pads and linings for contamina-
tion from brake fluid, and/or other fluids.
(3) Replace the brake pads linings if they are worn
to within 0.78 mm (1/32 in) of the rivet head.
(4) Operate the rear brake self-adjuster lever and
pivot. Test the operation of the self-adjuster screw for
ease of movement.
(5) Inspect the self-adjuster components for wear
or damage.
(6) Inspect the disc brake caliper dust boot for
damage and indications of brake fluid leakage. In-
spect the bushings and pins for corrosion, tears and a
binding condition.
(7) Pull the rear wheel cylinder dust boot back to
expose the wheel cylinder housing. Inspect for fluid
leaks. Inspect the pistons and cylinder bores.
(8) Inspect the brake differential warning valve
and housing for indications of leakage.
BRAKE FLUID HOSES/TUBING
The rubber brake fluid hoses should be inspected
for:
²Correct length
²Severe surface cracking
²Swelling
²Pulling
²Scuffing
²Excessively worn areas
If the hose has cracks or abrasions in the rub-
ber cover, the hose should be replaced.
(1) Inspect all the hoses for kinks, a distorted con-
dition and fluid leakage.
(2) Inspect the hose and tubing routing under the
vehicle. Verify that no hose/tubing is rubbing against
any exhaust or other underbody components.
PARKING BRAKE
(1) Engage the parking brake pedal and then re-
lease it.
(2) Test it for smooth operation and vehicle-holding
capability.
(3) Inspect the parking brake cables.
(4) With the parking brake released, the rear
wheels should
rotate without restriction. Adjust the parking brake
cable tension, if necessary (Fig. 9 and 10).
(5) Repair any parking brake malfunctions.
BRAKE OPERATIONAL TEST
(1) Drive the vehicle and test for proper brake ac-
tion.
Fig. 7 Reservoir Fluid LevelÐYJ (2.5L)
Fig. 8 Reservoir Fluid LevelÐYJ-XJ and Anti-Lock
Brake System
JLUBRICATION AND MAINTENANCE 0 - 31

FRONT SUSPENSION AND AXLE
CONTENTS
page page
AXLE NOISE/VIBRATION DIAGNOSIS........ 18
AXLE SPECIFICATIONS................... 49
FRONT WHEEL ALIGNMENT................ 5
GENERAL INFORMATION.................. 1MODEL 30 AXLE AND TUBE AXLE (2WD).... 22
TORQUE SPECIFICATIONS................ 49
XJ FRONT SUSPENSION.................. 11
YJ FRONT SUSPENSION.................. 15
GENERAL INFORMATION
FRONT SUSPENSION
XJ VEHICLES
The XJ front suspension is a link/coil design. This
suspension is use on Left Hand Drive (LHD) and
Right Hand Drive (RHD) vehicles. It is comprised of
(Fig. 1);
²Drive axle (4WD), tube axle (2WD)²Track bar
²Stabilizer bar
²Upper and lower suspension arms
²Coil springs
²Dual-action shock absorbers
²Jounce bumpers
The link/coil suspension allows each wheel to adapt
to different road surfaces without greatly affecting
Fig. 1 XJ Front Suspension (LHD)
JFRONT SUSPENSION AND AXLE 2 - 1