1999 Jeep Grand Cherokee WJ Service Manual.pdf

Welcome to the
1999 Jeept Grand Cherokee
Electronic Service Manual
Click on the logo to begin

GROUP TAB LOCATOR
IN Introduction
INa Introduction
0 Lubrication and Maintenance
2 Suspension
3 Differential and Driveline
5 Brakes
7 Cooling System
7a Cooling System
8A Battery
8Aa Battery
8B Starting Systems
8Ba Starting Systems
8C Charging System
8Ca Charging System
8D Ignition System
8E Instrument Panel Systems
8Ea Instrument Panel Systems
8F Audio Systems
8G Horn Systems
8H Vehicle Speed Control System
8J Turn Signal and Hazard Warning Systems
8K Wipers and Washer Systems
8L Lamps
8La Lamps
8M Passive Restraint Systems
8N Electrically Heated Systems
8O Power Distribution Systems
8P Power Lock Systems
8Q Vehicle Theft/Security Systems
8R Power Seat Systems
8S Power Window Systems
8T Power Mirror Systems
8U Chime/Buzzer Warning Systems
8V Overhead Console Systems
8W Wiring Diagrams
9 Engine
9a Engine
11 Exhaust System
11a Exhaust System and Turbo Charger
13 Frame and Bumpers
13a Frame and Bumpers
14 Fuel System
14a Fuel System - 2.5L Diesel Engine
19 Steering
19a Steering
21 Transmission and Transfer Case
21a Transmission and Transfer Case
22 Tires and Wheels
23 Body
24 Heating and Air Conditioning
24a Heating and Air Conditioning
25 Emission Control Systems
25a Emission Control System

INTRODUCTION
CONTENTS
page page
DESCRIPTION AND OPERATION
BODY CODE PLATE . . . . . . . . . . . . . . . . . . . . . . 2
VEHICLE IDENTIFICATION NUMBER (VIN) . . . . 1
VEHICLE SAFETY CERTIFICATION LABEL . . . . . 2
SERVICE PROCEDURES
THREADED HOLE REPAIR . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS
FASTENER IDENTIFICATION . . . . . . . . . . . . . . . . 2
FASTENER USAGE . . . . . . . . . . . . . . . . . . . . . . . 3
INTERNATIONAL VEHICLE CONTROL AND
DISPLAY SYMBOLS . . . . . . . . . . . . . . . . . . . . 2
METRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 6
TORQUE REFERENCES . . . . . . . . . . . . . . . . . . . . 8
VEHICLE IDENTIFICATION NUMBER (VIN)
DESCRIPTION
The Vehicle Identification Number (VIN) plate is
attached to the top left side of the instrument panel.
The VIN contains 17 characters that provide data
concerning the vehicle. Refer to the decoding chart to
determine the identification of a vehicle.
VEHICLE IDENTIFICATION NUMBER DECODING CHART
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1 = United States
2 Make J = Jeep
3 Vehicle Type 4 = MPV
4 Gross Vehicle Weight Rating G = 5001-6000 lbs.
5 Vehicle Line 2= Grand Cherokee 4X2 (LHD)
W = Grand Cherokee 4X4 (LHD)
6 Series 5 = Laredo
6 = Limited
7 Body Style 8 = 4dr Sport Utility
8 Engine S = 4.0 Liter
N = 4.7Liter
9 Check Digit
10 Model Year X = 1999
11 Assembly Plant C = Jefferson Assembly
12 thru 17 Vehicle Build Sequence
WJ INTRODUCTION 1

VEHICLE SAFETY CERTIFICATION LABEL
DESCRIPTION
A vehicle safety certification label (Fig. 1) is
attached to every Chrysler Corporation vehicle. The
label certifies that the vehicle conforms to all appli-
cable Federal Motor Vehicle Safety Standards. The
label also lists:
• Month and year of vehicle manufacture.
• Gross Vehicle Weight Rating (GVWR). The gross
front and rear axle weight ratings (GAWR’s) are
based on a minimum rim size and maximum cold tire
inflation pressure.
• Vehicle Identification Number (VIN).
• Type of vehicle.
• Type of rear wheels.
• Bar code.
• Month, Day and Hour (MDH) of final assembly.
• Paint and Trim codes.
• Country of origin.
The label is located on the driver-side door shut-
face.
BODY CODE PLATE
DESCRIPTION
A metal Body Code plate is located in the engine
compartment and attached to the top of the right
frame rail. The information listed on the plate (Fig.
2) is used for manufacturing and service purposes.
SERVICE PROCEDURES
THREADED HOLE REPAIR
Most stripped threaded holes can be repaired using
a Helicoilt. Follow the manufactures recommenda-
tions for application and repair procedures.
SPECIFICATIONS
DISPLAY SYMBOLS
The graphic symbols illustrated in the following
International Control and Display Symbols chart are
used to identify various instrument controls. The
symbols correspond to the controls and displays that
are located on the instrument panel.
FASTENER IDENTIFICATION
THREAD IDENTIFICATION
SAE and metric bolt/nut threads are not the same.
The difference is described in the Thread Notation
chart (Fig. 4).
Fig. 1 Vehicle Safety Certification Label
Fig. 2 Body Code Plate
2 INTRODUCTION WJ
DESCRIPTION AND OPERATION (Continued)

GRADE/CLASS IDENTIFICATION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts.
FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Figure art, specifications and torque references in
this Service Manual are identified in metric and SAE
format.
During any maintenance or repair procedures, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
Fig. 3
Fig. 4 Thread Notation Chart – SAE and Metric
WJ INTRODUCTION 3
SPECIFICATIONS (Continued)

4 INTRODUCTION WJ

FASTENER STRENGTH
WJ INTRODUCTION 5

METRIC SYSTEM
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million (Fig.
5).
The following chart will assist in converting metric
units to equivalent English and SAE units, or vise
versa.
Refer to the Conversion Chart to convert torque
values listed in metric Newton- meters (N·m). Also,
use the chart to convert between millimeters (mm)
and inches (in.)
Fig. 5 Metric Prefixes
CONVERSION FORMULAS AND EQUIVALENT VALUES
6 INTRODUCTION WJ

METRIC CONVERSION
WJ INTRODUCTION 7

TORQUE REFERENCES
Individual Torque Charts appear at the end of
many Groups. Refer to the Standard Torque Specifi-
cations Chart for torque references not listed in the
individual torque charts.
TORQUE SPECIFICATIONS
8 INTRODUCTION WJ

INTRODUCTION
CONTENTS
page page
BODY CODE PLATE . . . . . . . . . . . . . . . . . . . . . . . 2
VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . 1
VEHICLE SAFETY CERTIFICATION LABEL . . . . . . 2
SERVICE PROCEDURES
THREADED HOLE REPAIR . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS
FASTENER IDENTIFICATION. . . . . . . . . . . . . . . . . 3
FASTENER USAGE . . . . . . . . . . . . . . . . . . . . . . . . 3
DISPLAY SYMBOLS . . . . . . . . . . . . . . . . . . . . . 3
METRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 6
TORQUE REFERENCES. . . . . . . . . . . . . . . . . . . . . 8
VEHICLE IDENTIFICATION NUMBER (VIN)
DESCRIPTION
The Vehicle Identification Number (VIN) plate is
attached to the top left side of the instrument panel.
The VIN contains 17 characters that provide data
concerning the vehicle. Refer to the decoding chart to
determine the identification of a vehicle.
VEHICLE IDENTIFICATION NUMBER DECODING CHART
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1 = Austria
2 Make J = Jeep
3 Vehicle Type 4 = MPV
4 Gross Vehicle Weight Rating G = 5001-6000 lbs.
5 Vehicle Line 2 = Grand Cherokee 4X2 (LHD)
W = Grand Cherokee 4X4 (LHD)
7 = Grand Cherokee 4X2 (RHD)
8 = Grand Cherokee 4X4 (RHD)
6 Series 5 = Laredo
6 = Limited
7 Body Style 8 = 4dr Sport Utility
8 Engine S = 4.0L 6 cyl. (MPI) Unleaded
N = 4.7L 8 cyl. (MPI) Unleaded
4 = 3.1L 5 cyl. Turbo Diesel
V = 4.0L 6 cyl. (MPI) Leaded
9 Check Digit
10 Model Year X = 1999
11 Assembly Plant Y = Steyr Assembly
12 thru 17 Vehicle Build Sequence
WJ INTRODUCTION 0 - 1

VEHICLE SAFETY CERTIFICATION LABEL
DESCRIPTION
A vehicle safety certification label (Fig. 1) is
attached to every Chrysler Corporation vehicle. The
label certifies that the vehicle conforms to all appli-
cable Federal Motor Vehicle Safety Standards. The
label also lists:
• Month and year of vehicle manufacture.
• Gross Vehicle Weight Rating (GVWR). The gross
front and rear axle weight ratings (GAWR’s) are
based on a minimum rim size and maximum cold tire
inflation pressure.
• Vehicle Identification Number (VIN).
• Type of vehicle.
• Type of rear wheels.
• Bar code.
• Month, Day and Hour (MDH) of final assembly.
• Paint and Trim codes.
• Country of origin.
The label is located on the driver-side door shut-
face.
BODY CODE PLATE
DESCRIPTION
A metal Body Code plate is located in the engine
compartment and attached to the top of the right
frame rail. The information listed on the plate (Fig.
2) is used for manufacturing and service purposes.
SERVICE PROCEDURES
THREADED HOLE REPAIR
Most stripped threaded holes can be repaired using
a Helicoilt. Follow the manufactures recommenda-
tions for application and repair procedures.
Fig. 1 Vehicle Safety Certification Label
Fig. 2 Body Code Plate
0 - 2 INTRODUCTION WJ

SPECIFICATIONS
DISPLAY SYMBOLS
The graphic symbols illustrated in the following
International Control and Display Symbols chart are
used to identify various instrument controls. The
symbols correspond to the controls and displays that
are located on the instrument panel.
THREAD IDENTIFICATION
SAE and metric bolt/nut threads are not the same.
The difference is described in the Thread Notation
chart (Fig. 4).
GRADE/CLASS IDENTIFICATION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts.
FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Figure art, specifications and torque references in
this Service Manual are identified in metric and SAE
format.
During any maintenance or repair procedures, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
Fig. 3
Fig. 4 Thread Notation Chart – SAE and Metric

FASTENER STRENGTH

METRIC SYSTEM
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million (Fig.
5).
The following chart will assist in converting metric
units to equivalent English and SAE units, or vise
versa.
Refer to the Conversion Chart to convert torque
values listed in metric Newton- meters (N·m). Also,
use the chart to convert between millimeters (mm)
and inches (in.)
Fig. 5 Metric Prefixes
CONVERSION FORMULAS AND EQUIVALENT VALUES

METRIC CONVERSION

TORQUE REFERENCES
Individual Torque Charts appear at the end of
many Groups. Refer to the Standard Torque Specifi-
cations Chart for torque references not listed in the
individual torque charts.
TORQUE SPECIFICATIONS

LUBRICATION AND MAINTENANCE
CONTENTS
page page
JUMP STARTING, HOISTING AND TOWING . . . . 9
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . 4
LUBRICANTS
INDEX
page page
CLASSIFICATION OF LUBRICANTS . . . . . . . . . . . 1
FLUID FILL/CHECK LOCATIONS . . . . . . . . . . . . . 2
INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . 2
LUBRICATION POINT LOCATIONS . . . . . . . . . . . 2
PARTS AND LUBRICANT RECOMMENDATIONS . . 1
SPECIFICATIONS
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . 2
PARTS AND LUBRICANT RECOMMENDATIONS
DESCRIPTION
When service is required, Chrysler Corporation
recommends that only Mopart brand parts, lubri-
cants and chemicals be used. Mopar provides the
best engineered products for servicing Chrysler Cor-
poration vehicles.
CLASSIFICATION OF LUBRICANTS
DESCRIPTION
Only lubricants bearing designations defined by
the following organization should be used to service a
Chrysler Corporation vehicle.
• Society of Automotive Engineers (SAE)
• American Petroleum Institute (API) (Fig. 1)
• National Lubricating Grease Institute (NLGI)
(Fig. 2)
SAE VISCOSITY RATING
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.
• SAE 30 = single grade engine oil.
• SAE 10W-30 = multiple grade engine oil.
Chrysler Corporation only recommends multiple
grade engine oils.
API QUALITY CLASSIFICATION
This symbol (Fig. 1) on the front of an oil container
means that the oil has been certified by the Ameri-
can Petroleum Institute (API) to meet all the lubri-
cation requirements specified by Chrysler
Corporation.
Refer to Group 9, Engine for gasoline engine oil
specification.
GEAR LUBRICANTS
SAE ratings also apply to multiple grade gear
lubricants. In addition, API classification defines the
lubricants usage. Such as API GL-5 and SAE 80W-
90.
Fig. 1 API Symbol
WJ LUBRICATION AND MAINTENANCE 0 - 1

LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 2) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letter
“G”. Chassis lubricant is identified by the latter “L”.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
INTERNATIONAL SYMBOLS
DESCRIPTION
Chrysler Corporation uses international symbols to
identify engine compartment lubricant and fluid
check and fill locations (Fig. 3).
FLUID FILL/CHECK LOCATIONS
DESCRIPTION
Fluid fill/check locations are located in each appli-
cable group.
LUBRICATION POINT LOCATIONS
DESCRIPTION
Lubrication point locations are located in each
applicable group.
SPECIFICATIONS
FLUID CAPACITIES
FUEL TANK
All . . . . . . . . . . . . . . . . . . . . . . . . . . 78 L (20.5 gal.)
ENGINE OIL W/FILTER CHANGE
4.0L . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 L (6.0 qts.)
4.7L . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 L (6.0 qts.)
COOLING SYSTEM
CAUTION: Vehicle may be equipped with long life
coolant. Extended life coolant is identified by an
orange color. Normal coolant is identified by a
greenish color. It is recommended that the two
types of coolant not be mixed.
4.0L . . . . . . . . . . . . . . . . . . . . . . . 12.3 L (13.0 qts.)*
4.7L . . . . . . . . . . . . . . . . . . . . . . . 12.3 L (13.0 qts.)*
*Includes 2.2 L (2.3 qts.) for coolant recovery bot-
tle.
AUTOMATIC TRANSMISSION
Dry fill capacity. *
42RE . . . . . . . . . . . . . . . . . . . . 9.1-9.5L (19-20 pts.)
45RFE . . . . . . . . . . . . . . . . . . . . . 13.33 L (28.0 pts.)
* Depending on type and size of internal cooler,
length and inside diameter of cooler lines, or use of
an auxiliary cooler, these figures may vary. Refer to
Group 21, Transmission for proper fluid fill proce-
dure.
TRANSFER CASE
242 NVG . . . . . . . . . . . . . . . . . . . . . . 1.4 L (3.0 pts.)
247 NVG . . . . . . . . . . . . . . . . . . . . . . 1.1 L (2.5 pts.)
FRONT AXLE
186 FBI . . . . . . . . . . . . . . . . . . . . . . 1.18 L (2.5 pts.)
186FBI‡ . . . . . . . . . . . . . . . . . . . . . 1.19L (2.51 pts.)
‡If the vehicle is equipped with VARI-LOK, include
0.07L (0.15 pts.) of friction modifier.
Fig. 2 NLGI Symbol
Fig. 3 International Symbols
0 - 2 LUBRICATION AND MAINTENANCE WJ

REAR AXLE
198 RBI* . . . . . . . . . . . . . . . . . . . . . . 1.6 L (3.5 pts.)
198RBI ‡ . . . . . . . . . . . . . . . . . . . . 1.78L (3.76 pts.)
226 RBA* . . . . . . . . . . . . . . . . . . . 2.24 L (4.75 pts.)
226RBA ‡‡ . . . . . . . . . . . . . . . . . . . 2.25L (4.75 pts.)
* If the vehicle is equipped with TRAC-LOK,
include 0.11 L (0.25 pts.) of friction modifier.
‡ If the vehicle is equipped with a VARI-LOK,
include 0.09L (0.19 pts.) of friction modifier.
‡‡ If the vehicle is equipped with a VARI-LOK,
include 0.12L (0.25 pts.) of friction modifier.
NOTE: Vehicles with trailer tow, must use a syn-
thetic lubricant. Refer to Group 3, Differential and
Driveline for service procedures.
POWER STEERING
Power steering fluid capacities are dependent on
engine/chassis options as well as steering gear/cooler
options. Depending on type and size of internal
cooler, length and inside diameter of cooler lines, or
use of an auxiliary cooler, these capacities may vary.
Refer to Section 19 of the service manual for proper
fill and bleed procedures.

MAINTENANCE SCHEDULES
INDEX
page page
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . 4
SPECIFICATIONS
SCHEDULE—A . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SCHEDULE—B . . . . . . . . . . . . . . . . . . . . . . . . . . 6
UNSCHEDULED INSPECTION . . . . . . . . . . . . . . . 4
MAINTENANCE SCHEDULES
There are two maintenance schedules that show
proper service for the Grand Cherokee.
First is Schedule “A”. It lists all the scheduled
maintenance to be performed under “normal” operat-
ing conditions.
Second is Schedule “B”. It is a schedule for vehi-
cles that are operated under the following conditions:
• Frequent short trip driving less than 5 miles (8
km)
• Frequent driving in dusty conditions
• Extensive idling
• Trailer towing
• Sustained high speed operation
• Off road driving
• Desert operation
• Frequent starting and stopping
• Cold climate operation
• Commercial service
Use the schedule that best describes the driving
conditions.
Where time and mileage are listed, follow the
interval that occurs first.
EMISSION CONTROL SYSTEM MAINTENANCE
The scheduled emission maintenance listed in bold
type on the Maintenance 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.
SPECIFICATIONS
UNSCHEDULED INSPECTION
AT EACH STOP FOR FUEL
• Check engine oil level, add as required.
• Check windshield washer solvent and add if
required.
ONCE A MONTH
• Check tire pressure (including spare) and look
for unusual wear or damage.
• Inspect battery and clean and tighten terminals
as required.
• Check fluid levels of coolant reservoir, power
steering and transmission and add as needed.
AT EACH OIL CHANGE
• Inspect exhaust system.
• Inspect brake hoses.
• Rotate the tires at each oil change interval
shown on Schedule—A (7,500 miles) or every other
interval shown on Schedule—B (6,000 miles).
• Check coolant level, hoses and clamps.
• Lubricate suspension ball joints.
• After completion of off-road (4WD) operation, the
underside of the vehicle should be thoroughly
inspected. Examine threaded fasteners for looseness.
SCHEDULE—A
7,500 miles (12 000 km) or at 6 months
• Change engine oil.
• Replace engine oil filter.
15,000 Miles (24 000 km) or at 12 months
• Lubricate upper knuckle ball stud.
• Inspect brake linings.

• Replace engine air cleaner element.
• Replace spark plugs.
• Inspect and adjust drive belt (4.0L only).
• Drain and refill automatic transmission fluid
and change filter.
• Drain and refill transfer case fluid.
• Flush and replace engine coolant at 36 months,
regardless of mileage.
• Flush and replace engine coolant if not done at
36 months.
• Inspect PCV valve and replace if necessary
(4.7L only).*
and change filter.
• Inspect brake linings
• Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
change.
• Inspect and replace drive belt if needed (4.7L
only).
and change filter.
• Inspect and replace drive belt if not previously
replaced (4.7L only).
change.
change.
(4.7L only).*
and change filter.

*This maintenance is recommended, but is not
required to maintain warranty on the PCV valve.
IMPORTANT: Inspection and service should also
be performed anytime a malfunction is observed or
suspected.
SCHEDULE—B
3,000 Miles (5 000 km)
• Lubricate steering linkage.
6,000 Miles (10 000 km)
9,000 Miles (14 000 km)
12,000 Miles (19 000 km)
and change filter.
• Drain and refill front and rear axles.
15,000 miles (24 000 km)
• Inspect engine air cleaner element, replace
as necessary.
18,000 Miles (29 000 km)
21,000 Miles (34 000 km)
24,000 Miles (38 000 km)
and change filter.
27,000 Miles (43 000 km)
30,000 Miles (48 000 km)
33,000 Miles (53 000 km)
36,000 Miles (58 000 km)
and change filter.
39,000 Miles (62 000 km)
42,000 Miles (67 000 km)
45,000 Miles (72 000 km)
as necessary.
48,000 Miles (77 000 km)
and change filter.
51,000 Miles (82 000 km)
• Flush and replace engine coolant.
54,000 Miles (86 000 km)

57,000 Miles (91 000 km)
60,000 Miles (96 000 km)
(4.7L only).*
and change filter.
63,000 Miles (101 000 km)
66,000 Miles (106 000 km)
69,000 Miles (110 000 km)
72,000 Miles (115 000 km)
and change filter.
75,000 Miles (120 000 km)
as necessary.
78,000 Miles (125 000 km)
81,000 Miles (130 000 km)
84,000 miles (134 000 km)
and change filter.
87,000 Miles (139 000 km)
90,000 Miles (144 000 km)
• Inspect and replace drive belt if necessary (4.7L
only).
93,000 Miles (149 000 km)
96,000 Miles (154 000 km)
and change filter.
99,000 Miles (158 000 km)
102,000 Miles (163 000 km)
105,000 Miles (168 000 km)
as necessary.

108,000 Miles (173 000 km)
and change filter.
111,000 Miles (178 000 km)
114,000 Miles (182 000 km)
117,000 Miles (187 000 km)
120,000 Miles (192 000 km)
and change filter.
*This maintenance is recommended, but is not
required to maintain warranty on the PCV valve.
IMPORTANT: Inspection and service should also
be performed anytime a malfunction is observed or
suspected.

JUMP STARTING, HOISTING AND TOWING
INDEX
page page
SERVICE PROCEDURES
EMERGENCY TOW HOOKS . . . . . . . . . . . . . . . . 12
FOUR-WHEEL-DRIVE VEHICLE TOWING . . . . . . 11
HOISTING RECOMMENDATIONS . . . . . . . . . . . 12
JUMP STARTING PROCEDURE . . . . . . . . . . . . . . 9
TOWING RECOMMENDATIONS . . . . . . . . . . . . . 10
TWO-WHEEL-DRIVE VEHICLE TOWING . . . . . . 10
SERVICE PROCEDURES
JUMP STARTING PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT
JUMP START A FROZEN BATTERY, PERSONAL
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 BAT-
TERY. REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT. WHEN
USING A HIGH OUTPUT BOOSTING DEVICE, DO
NOT ALLOW BATTERY VOLTAGE TO EXCEED 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
inspect engine compartment for:
• Battery cable clamp condition, clean if necessary.
• Frozen battery.
• Yellow or bright color test indicator, if equipped.
• Low battery fluid level.
• Generator drive belt condition and tension.
• Fuel 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, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
(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.
Review 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).
(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
Fig. 1 Jumper Cable Clamp Connections

(7) 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:
• Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
• When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
• Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
TOWING RECOMMENDATIONS
A vehicle equipped with SAE approved wheel lift-
type towing equipment can be used to tow WJ vehi-
cles. When towing a 4WD vehicle using a wheel-lift
towing device, use tow dollies under the opposite end
of the vehicle. A vehicle with flatbed device can also
be used to transport a disabled vehicle (Fig. 2).
SAFETY PRECAUTIONS
CAUTION: The following safety precautions must
be observed when towing a vehicle:
• Secure loose and protruding parts.
• Always use a safety chain system that is inde-
pendent of the lifting and towing equipment.
• Do not allow towing equipment to contact the
disabled vehicle’s fuel tank.
• Do not allow anyone under the disabled vehicle
while it is lifted by the towing device.
• Do not allow passengers to ride in a vehicle
being towed.
• Always observe state and local laws regarding
towing regulations.
• Do not tow a vehicle in a manner that could
jeopardize the safety of the operator, pedestrians or
other motorists.
• Do not attach tow chains, T-hooks, or J-hooks to
a bumper, steering linkage, drive shafts or a non-re-
inforced frame hole.
• Do not tow a heavily loaded vehicle. Use a flat-
bed device to transport a loaded vehicle.
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
increase 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
degrees.
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 device can be
used on 4WD vehicles provided the trailing wheels
are off the ground and positioned in tow dol-
lies.
TWO-WHEEL-DRIVE VEHICLE TOWING
Chrysler Corporation recommends that a vehicle be
towed with the rear end lifted, whenever possible.
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION (AUTO-
MATIC TRANSMISSION) OR A FORWARD DRIVE
GEAR (MANUAL TRANSMISSION).
WARNING: ENSURE VEHICLE IS ON A LEVEL SUR-
FACE OR THE WHEELS ARE BLOCKED TO PRE-
VENT VEHICLE FROM ROLLING.
Fig. 2 Tow Vehicles With Approved Equipment
SERVICE PROCEDURES (Continued)

TWO WHEEL DRIVE TOWING-REAR END LIFTED
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
2WD 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 wheel lift device to rear wheels.
(2) Place the transmission in neutral.
(3) Raise vehicle to towing position.
(4) Attach safety chains. Route chains so not to
interfere with tail pipe when vehicle is lifted.
(5) Turn the ignition switch to the OFF position to
unlock the steering wheel.
(6) Secure steering wheel in straight ahead posi-
tion with a clamp device designed for towing.
(7) Place transmission in park.
TWO WHEEL DRIVE TOWING-FRONT END LIFTED
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.
(3) Raise the rear of the vehicle off the ground and
install tow dollies under rear wheels.
(4) Attach wheel lift device to front wheels and
raise vehicle to towing position.
(5) Attach the safety chains.
FOUR-WHEEL-DRIVE VEHICLE TOWING
Chrysler Corporation recommends that a vehicle be
transported on a flat-bed device. A Wheel-lift device
can be used provided the trailing wheels are off
the ground and positioned in tow dollies.
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION.
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.
FOUR WHEEL DRIVE TOWING—REAR END LIFTED
(1) Attach wheel lift device to front wheels.
(3) Raise the front of the vehicle off the ground
and install tow dollies under front wheels.
(4) Attach wheel lift device to rear wheels and
(5) Attach safety chains. Route chains so not to
interfere with tail pipe when vehicle is lifted.
FOUR WHEEL DRIVE TOWING—FRONT END
LIFTED
(3) Raise the rear of the vehicle off the ground and
install tow dollies under rear wheels.
(4) Attach wheel lift device to front wheels and
(5) Attach the safety chains.

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 emer-
gency tow hooks (Fig. 3). The tow hooks should be
used for EMERGENCY purposes only.
CAUTION: DO NOT use emergency tow hooks for
tow truck hook-up or highway towing.
HOISTING RECOMMENDATIONS
FLOOR JACK
When properly positioned, a floor jack can be used
to lift a WJ vehicle (Fig. 4). Support the vehicle in
the raised position with jack stands at the front and
rear ends of the frame rails.
CAUTION: Do not attempt to lift a vehicle with a
floor jack positioned under:
• An axle tube.
• Aluminum differential.
• A body side sill.
• A steering linkage component.
• A drive shaft.
• The engine or transmission oil pan.
• The fuel tank.
• A front suspension arm.
HOIST
A vehicle can be lifted with:
• A single-post, frame-contact hoist.
• A twin-post, chassis hoist.
• A ramp-type, drive-on hoist.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly
(Fig. 4).
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
DEVICE WHEN THESE CONDITIONS EXIST.
Fig. 3 Emergency Tow Hooks
Fig. 4 Correct Vehicle Lifting Locations

SUSPENSION
CONTENTS
page page
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 4
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 15
ALIGNMENT
INDEX
page page
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 1
SERVICE PROCEDURES
PRE-ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . 2
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WHEEL ALIGNMENT
Wheel alignment involves the correct positioning of
the wheels in relation to the vehicle. The positioning
is accomplished through suspension and steering
linkage adjustments. An alignment is considered
essential for efficient steering, good directional stabil-
ity and to minimize tire wear. The most important
measurements of an alignment are caster, camber
and toe position (Fig. 1).
• CASTER is the forward or rearward tilt of the
steering knuckle from vertical. Tilting the top of the
knuckle rearward provides positive caster. Tilting the
top of the knuckle forward provides negative caster.
Caster is a directional stability angle. This angle
enables the front wheels to return to a straight
ahead position after turns.
• CAMBER is the inward or outward tilt of the
wheel relative to the center of the vehicle. Tilting the
top of the wheel inward provides negative camber.
Tilting the top of the wheel outward provides positive
camber. Incorrect camber will cause wear on the
inside or outside edge of the tire. The angle is not
adjustable, damaged component(s) must be replaced
to correct the camber angle.
• WHEEL TOE POSITION is the difference
between the leading inside edges and trailing inside
edges of the front tires. Incorrect wheel toe position
is the most common cause of unstable steering and
uneven tire wear. The wheel toe position is the final
front wheel alignment adjustment.
• STEERING AXIS INCLINATION ANGLE is
measured in degrees and is the angle that the steer-
ing knuckles are tilted. The inclination angle has a
fixed relationship with the camber angle. It will not
change except when a spindle or ball stud is dam-
aged or bent. The angle is not adjustable, damaged
component(s) must be replaced to correct the steering
axis inclination angle.
• THRUST ANGLE is the angle of the rear axle
relative to the centerline of the vehicle. Incorrect thrust
angle can cause off-center steering and excessive tire
wear. This angle is not adjustable, damaged compo-
nent(s) must be replaced to correct the thrust angle.
CAUTION: Never attempt to modify suspension or
steering components by heating or bending.
CAUTION: Components attached with a nut and
cotter pin must be torqued to specification. Then if
the slot in the nut does not line up with the cotter
pin hole, tighten nut until it is aligned. Never loosen
the nut to align the cotter pin hole.
NOTE: Periodic lubrication of the front suspension/
steering system components may be required. Rub-
ber bushings must never be lubricated. Refer to
Group 0, Lubrication And Maintenance for the rec-
ommended maintenance schedule.
WJ SUSPENSION 2 - 1

SERVICE PROCEDURES
PRE-ALIGNMENT
Before starting wheel alignment, the following
inspection and necessary corrections must be com-
pleted. Refer to Suspension and Steering System
Diagnosis Chart for additional information.
(1) Inspect tires for size and tread wear.
(2) Set tire air pressure.
(3) Inspect front wheel bearings for wear.
(4) Inspect front wheels for excessive radial or lat-
eral runout and balance.
(5) Inspect ball studs, linkage pivot points and
steering gear for looseness, roughness or binding.
(6) Inspect suspension components for wear and
noise.
WHEEL ALIGNMENT
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 three times. Always release the bumper in the
down position.
To obtain an accurate alignment, a 4 wheel align-
ment machine must be used and the equipment cali-
bration verified.
CAMBER
The wheel camber angle is preset. This angle is not
adjustable and cannot be altered.
CASTER
The wheel caster angle is preset. This angle is not
adjustable and cannot be altered.
TOE POSITION
NOTE: For an accurate wheel toe position adjust-
ment the engine must be engine running.
(1) Apply parking brakes.
(2) Start the engine and turn wheels both ways
before straightening the steering wheel. Center and
secure the steering wheel.
(3) Loosen the tie rod adjustment sleeve clamp
bolts (Fig. 2).
(4) Turn the sleeve to obtain the preferred positive
TOE-IN specification. Position the clamp bolts as
shown (Fig. 2) for proper clearance.
(5) Tighten the clamp bolts to 68 N·m (50 ft. lbs.).
NOTE: Make sure the toe setting does not change
during clamp tightening.
Fig. 1 Wheel Alignment Measurements
2 - 2 SUSPENSION WJ

(6) Verify alignment specifications, then turn the
engine off.
STEERING WHEEL CENTERING
NOTE: The steering wheel can be centered without
affecting the toe position.
(1) Loosen the drag link adjustment sleeve clamp
bolts.
(2) Turn the adjustment sleeve to center the
wheel.
(3) Position the clamp bolts as shown (Fig. 2) for
proper clearance.
(4) Tighten the clamp bolts to 68 N·m (50 ft. lbs.).
(5) Road test the vehicle to verify the wheel is cen-
tered.
SPECIFICATIONS
ALIGNMENT
NOTE: Specifications are in degrees.
FRONT WHEELS - STANDARD SUSPENSION
FRONT WHEELS - UP-COUNTRY SUSPENSION
REAR AXLE
Fig. 2 Steering Linkage
ANGLE PREFERRED RANGE
CASTER NA +6.0° to +8.0°
CAMBER NA 0° to −0.5°
TOE-IN
(each wheel)
+0.125° 0° to +0.25°
Toe Differential Left to Right .05°
ANGLE PREFERRED RANGE
CASTER NA +5.5° to +7.5°
CAMBER NA 0° to −0.5°
TOE-IN
(each wheel)
+0.125° 0° to +0.25°
Toe Differential Left to Right .05°
ANGLE RANGE
CAMBER 0° to −0.5
THRUST ANGLE 6 0.25°
TOTAL TOE-IN 0° to +0.5°
WJ SUSPENSION 2 - 3

FRONT SUSPENSION
INDEX
page page
COIL SPRINGS AND ISOLATORS . . . . . . . . . . . . 5
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . 4
HUB/BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
JOUNCE BUMPER . . . . . . . . . . . . . . . . . . . . . . . . 5
LOWER SUSPENSION ARMS AND BUSHINGS . . 5
SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . . 4
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . 5
STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . 5
TRACK BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
UPPER SUSPENSION ARMS AND BUSHINGS . . 5
DIAGNOSIS AND TESTING
SUSPENSION AND STEERING SYSTEM . . . . . . . 6
REMOVAL AND INSTALLATION
COIL SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FRONT AXLE BUSHING . . . . . . . . . . . . . . . . . . . 10
HUB BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . 8
SERVICE WARNINGS AND CAUTIONS . . . . . . . . 7
SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . 7
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 11
STEERING KNUCKLE AND BALL JOINTS . . . . . . 8
TRACK BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . . 9
WHEEL MOUNTING STUDS . . . . . . . . . . . . . . . . 12
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 13
SPECIAL TOOLS
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . 13
FRONT SUSPENSION
The front suspension (Fig. 1) is a link/coil design
comprised of:
• Drive axle
• Shock absorbers
• Coil springs
• Upper and lower suspension arms
• Stabilizer bar
• Track bar
• Jounce bumpers
CAUTION: Components attached with a nut and
cotter pin must be torqued to specification. Then if
the slot in the nut does not line up with the cotter
pin hole, tighten nut until it is aligned. Never loosen
the nut to align the cotter pin hole.
CAUTION: Suspension components with rubber
bushings must be tightened with the vehicle at nor-
mal ride height. It is important to have the springs
supporting the weight of the vehicle when the fas-
teners are torqued. If springs are not at their normal
ride position, vehicle ride comfort will be affected
and cause premature bushing wear.
SHOCK ABSORBERS
DESCRIPTION
The top of the shock absorbers are bolted to the
body. The bottom of the shocks are bolted to the axle
brackets. The standard shocks have conventional
twin tube construction and are low pressure gas
charged. Gas charging prevents cavitation during
rough road operation. Up-Country shocks are mono
tube design and are high pressure gas charged.
OPERATION
The shock absorbers dampen jounce and rebound
motion of the vehicle over various road conditions
and limit suspension rebound travel.
Fig. 1 Front Suspension
2 - 4 SUSPENSION WJ

JOUNCE BUMPER
DESCRIPTION
They are mounted under the unibody rails to mini-
mize transmission of noise to the passenger compart-
ment.
OPERATION
The jounce bumpers are used to limit suspension
travel in compression.
COIL SPRINGS AND ISOLATORS
DESCRIPTION
The coil springs mount up in the wheelhouse which
is part of the unitized body bracket. A rubber dough-
nut isolator is located between the top of the spring
and the body. The bottom of the spring seats on a
axle isolator made of rubber with a steel insert.
OPERATION
The coil springs control ride quality and maintain
proper ride height. The isolators provide road noise iso-
lation.
STEERING KNUCKLE
DESCRIPTION
The knuckle is a single casting with legs machined
for the upper and lower ball joints. The knuckle also
has machined mounting locations for the front brake
calipers and hub bearing.
OPERATION
The steering knuckle pivot between the upper and
lower ball joint. Steering linkage attached to the
knuckle allows the vehicle to be steered.
LOWER SUSPENSION ARMS AND BUSHINGS
DESCRIPTION
The lower suspension arms are hydroformed steel
and use voided oval bushings at one end of the arm.
OPERATION
The bushings provide isolation from the axle. The
arms mount to the unibody frame rail bracket and
the axle brackets. The arm and bushings provide
location and react to loads from the axle.
UPPER SUSPENSION ARMS AND BUSHINGS
DESCRIPTION
The upper suspension arms are hydroformed steel
and use rubber bushings at each end of the arm.
OPERATION
The arms mount to the unibody frame rail bracket
and the axle brackets. The arm and bushings provide
location and react to loads from the axle. The bush-
ings provide isolation from the axle.
STABILIZER BAR
DESCRIPTION
The bar extends across the front underside of the
chassis and is mounted to the frame rails. Links are
connected from the bar to the axle brackets. The sta-
bilizer bar and links are isolated by rubber bushings.
OPERATION
The stabilizer bar is used to control vehicle body roll
during turns. The spring steel bar helps to control the
vehicle body in relationship to the suspension.
TRACK BAR
DESCRIPTION
The bar is attached to a frame rail bracket and
axle bracket. The bar is forged and has non replace-
able isolator bushings at both ends.
OPERATION
The track bar is used to control front axle lateral
movement and provides cross car location of the axle
assembly.
HUB/BEARING
DESCRIPTION
The bearing used on the front hub of this vehicle is
the combined hub and bearing unit type assembly. This
unit assembly combines the front wheel mounting hub
(flange) and the front wheel bearing into a one piece
unit. The wheel mounting studs are the only replace-
able component of the hub/bearing assembly.
OPERATION
The hub/bearing assembly is mounted to the steer-
ing knuckle and is retained by three mounting bolts
accessible from the back of the steering knuckle. The
hub/bearing unit is not serviceable and must be
replaced as an assembly if the bearing or the hub is
determined to be defective.
WJ SUSPENSION 2 - 5

SUSPENSION AND STEERING SYSTEM
CONDITION POSSIBLE CAUSES CORRECTION
FRONT END NOISE 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
2. Loose or worn steering or suspension
components.
2. Tighten or replace components as necessary.
EXCESSIVE PLAY IN
STEERING
1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
components.
3. Loose or worn steering gear. 3. Adjust or replace steering gear.
FRONT WHEELS SHIMMY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
components.
3. Tires worn or out of balance. 3. Replace or balance tires.
4. Alignment. 4. Align vehicle to specifications.
5. Leaking steering dampener. 5. Replace steering dampener.
VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
components.
3. Tire pressure. 3. Adjust tire pressure.
EXCESSIVE STEERING
EFFORT
1. Loose or worn steering gear. 1. Adjust or replace steering gear.
2. Power steering fluid low. 2. Add fluid and repair leak.
3. Column coupler binding. 3. Replace coupler.
VEHICLE PULLS TO ONE
SIDE
3. Loose, worn or bent steering/
suspension components.
3. Inspect, tighten or replace components as
necessary.
4. Radial tire lead. 4. Rotate or replace tire as necessary.
5. Brake pull. 5. Repair brake as necessary.
6. Weak or broken spring. 6. Replace spring.
KNOCKING, RATTLING OR
SQUEAKING
1. Worn shock bushings. 1. Replace shock.
necessary.
3. Shock valve. 3. Replace shock.
IMPROPER TRACKING 1. Loose, worn or bent track bar. 1. Inspect, tighten or replace component as
necessary.
necessary.
2 - 6 SUSPENSION WJ

SERVICE WARNINGS AND CAUTIONS
SHOCK ABSORBER
REMOVAL
(1) Remove the nut, retainer and grommet from
the shock stud in the engine compartment (Fig. 2).
(2) Raise and support the front axle.
(3) Remove the lower mounting nuts from the axle
bracket (Fig. 3). Remove the shock absorber.
INSTALLATION
(1) Position the lower retainer and grommet on the
shock stud. Insert the shock absorber through the
shock tower hole.
(2) Install the lower shock studs into the axle
bracket.
(3) Install the mounting nuts and tighten to 28
N·m (250 in. lbs.).
(4) Remove support and lower the vehicle.
(5) Install the upper grommet, retainer and nut on
the stud in the engine compartment. Tighten the nut
to 35 N·m (26 ft. lbs.).
COIL SPRINGS
REMOVAL
(1) Raise and support the vehicle. Position a
hydraulic jack under the axle to support it.
(2) Remove the wheel and tire assemblies.
(3) Remove stabilizer bar links mounting nuts and
bolts from the axle brackets.
(4) Remove shock absorbers lower mounting nuts
from the axle brackets.
(5) Remove the track bar mounting bolt from the
axle bracket.
(6) Lower the axle until the spring is free from the
upper mount and isolator (Fig. 4).
(7) Remove the spring from the vehicle.
(8) Remove and inspect the upper and lower
spring isolators.
INSTALLATION
(1) Install the upper isolator.
(2) Install the lower isolator with the isolator loca-
tor nub in the axle pad hole (Fig. 5).
Fig. 2 Upper Shock Mounting
Fig. 3 Lower Shock Mounting
Fig. 4 Front Coil Spring
WJ SUSPENSION 2 - 7

(3) Position the coil spring on the axle spring pad.
CAUTION: Ensure the spring is positioned on the
lower isolator with the end of the spring coil
against the isolator spring locator (Fig. 6).
(4) Raise the axle and guide the springs onto the
spring upper mounts and lower shock studs into the
axle brackets.
(5) Install the shock absorbers lower mounting
nuts.
(6) Install the stabilizer bar link to the axle
bracket and install the mounting bolts and nuts.
(7) Install the track bar to the axle bracket and
install the mounting bolt.
NOTE: It may be necessary to pry the axle assem-
bly over to install the track bar bolt.
(8) Tighten all suspension components to proper
torque.
(9) Install the wheel and tire assemblies.
(10) Remove support and lower vehicle.
STEERING KNUCKLE AND BALL JOINTS
KNUCKLE REMOVAL
(1) Raise and support the vehicle.
(2) Remove wheel and tire assembly.
(3) Remove hub bearing.
(4) Remove the axle, shaft refer to Group 3 Differ-
ential and Driveline.
(5) Remove the tie rod on left steering knuckle.
Remove the tie rod and drag link on right steering
knuckle.
(6) Remove the cotter pins from the upper and
lower ball studs.
(7) Remove the upper and lower ball stud nuts.
(8) Strike the steering knuckle with a brass ham-
mer to loosen knuckle from the ball studs. Remove
knuckle from ball studs.
UPPER BALL JOINT REPLACEMENT
(1) Position tools as shown to remove and install
ball joint (Fig. 7).
LOWER BALL JOINT REPLACEMENT
(1) Position tools as shown to remove and install
ball joint (Fig. 8).
KNUCKLE INSTALLATION
(1) Position the steering knuckle on the ball joints.
(2) Install and tighten the bottom retaining nut to
109 N·m (80 ft. lbs.) torque. Install new cotter pin.
(3) Install and tighten the top retaining nut to 101
N·m (75 ft. lbs.) torque. Install new cotter pin.
(4) Install the axle shaft, refer to Group 3 Differ-
ential and Driveline.
(5) Install the hub bearing.
(6) Install the tie rod on the left steering knuckle.
Install the tie rod and drag link end on the right
steering knuckle.
(7) Install wheel and tire assembly.
LOWER SUSPENSION ARM
REMOVAL
(1) Raise the vehicle and support the front axle.
(2) Remove the lower suspension arm nut and bolt
from the axle bracket (Fig. 9).
(3) Remove the nut and bolt from the frame rail
bracket and remove the lower suspension arm (Fig. 9).
Fig. 5 Lower Isolator
Fig. 6 Isolator Spring Locator
2 - 8 SUSPENSION WJ
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Position the lower suspension arm in the axle
bracket and frame rail bracket.
NOTE: The end of the arm with the oval bushing
attaches to the axle bracket.
(2) Install the axle bracket bolt and nut finger
tight.
(3) Install the frame rail bracket bolt and nut fin-
ger tight.
(5) With the vehicle on the ground tighten the axle
bracket nut and the frame bracket bolt to 176 N·m
(130 ft. lbs.).
(6) Check the alignment if new parts were
installed.
UPPER SUSPENSION ARM
REMOVAL
(1) Raise vehicle and support the axle.
(2) Remove the upper suspension arm mounting
nut and bolt (Fig. 10) from the axle bracket.
(3) Remove the nut and bolt (Fig. 10) at the frame
rail and remove the upper suspension arm.
INSTALLATION
(1) Position the upper suspension arm at the axle
and frame rail.
(2) Install the bolts and finger tighten the nuts.
(3) Remove the supports and lower the vehicle.
(4) With the vehicle on the ground tighten the axle
bracket nut and the frame bracket bolt to 61 N·m (45
ft. lbs.).
(5) Check the alignment if new parts were
installed.
Fig. 7 Upper Ball Joint Remove/Install
WJ SUSPENSION 2 - 9
1999 Jeep Grand Cherokee
Publication No. 81-370-9147
TSB 26-10-98 October, 1998

FRONT AXLE BUSHING
REMOVAL
(1) Remove the upper suspension arm from axle.
(2) Position Spacer 8279 over the axle bushing on
a 4x2 vehicle and right side on a 4x4 vehicle.
(3) Place Receiver 7932-1 over flanged end of the
bushing (Fig. 11).
(4) Place small end of Remover/Install 7932-2
against other side of the bushing.
(5) Install bolt 7604 through remover, bushing and
receiver.
(6) Install Long Nut 7603 and tighten nut too pull
bushing out of the axle bracket.
(7) Remove nut, bolt, receiver, remover and bushing.
Fig. 8 Lower Ball Joint Remove/Install
Fig. 9 Lower Suspension Arm Fig. 10 Upper Suspension Arm
2 - 10 SUSPENSION WJ

NOTE: On 4x2 vehicle and right side of 4x4 vehicle,
leave Spacer 8279 in position for bushing installa-
tion.
INSTALLATION
(1) Place Receiver 7932-1on the other side of the
axle bracket.
(2) Position new bushing up to the axle bracket.,
and large end of Remover/Install 7932-2 against the
bushing (Fig. 12).
(3) Install bolt 7604 through receiver, bushing and
installer.
(4) Install Long Nut 7603 and tighten nut to draw
the bushing into the axle bracket.
(5) Remove tools and install the upper suspension
arm.
STABILIZER BAR
REMOVAL
(2) Remove link nuts and bolts (Fig. 13) and
remove the links.
(3) Remove the stabilizer bar retainer bolts (Fig.
13) from the frame rails and remove the stabilizer
bar.
INSTALLATION
(1) Position the stabilizer bar on the frame rail
and install the retainers and bolts. Ensure the bar is
centered with equal spacing on both sides. Tighten
the bolts to 92 N·m (68 ft. lbs.).
(2) Install the links onto the stabilizer bar and
axle brackets and install the bolts and nuts finger
tight.
(4) With the vehicle on the ground tighten the sta-
bilizer bar link nuts to 106 N·m (78 ft. lbs.).
TRACK BAR
REMOVAL
(2) Remove the nut and bolt from the frame rail
bracket (Fig. 14).
(3) Remove the bolt from the axle shaft tube
bracket (Fig. 15). Remove the track bar.
INSTALLATION
(1) Install the track bar to the axle tube bracket.
Install the retaining bolt finger tight.
(2) Install track bar to the frame rail bracket.
Install the bolt and nut finger tight.
Fig. 11 Bushing Removal
Fig. 12 Bushing Installation
Fig. 13 Stabilizer Bar
WJ SUSPENSION 2 - 11

NOTE: It may be necessary to pry the axle assem-
bly over to install the track bar to the frame rail
bracket.
(4) With the vehicle on the ground tighten the nut
at the frame rail bracket and to the bolt at the axle
bracket to 100 N·m (74 ft. lbs.).
(5) Check alignment specifications if a new track
bar was installed.
HUB BEARING
REMOVAL
(2) Remove the wheel and tire assembly.
(3) Remove the brake caliper, caliper anchor, rotor
and ABS wheel speed sensor, refer to Group 5
Brakes.
(4) Remove the cotter pin, nut retainer and axle
hub nut.
(5) Remove the hub bearing mounting bolts from
the back of the steering knuckle. Remove hub bear-
ing (Fig. 16) from the steering knuckle and off the
axle shaft.
INSTALLATION
(1) Install the hub bearing to the knuckle.
(2) Install the hub bearing to knuckle bolts and
tighten to 102 N·m (75 ft. lbs.).
(3) Install the hub washer and nut. Tighten the
hub nut to 237 N·m (175 ft. lbs.). Install the nut
retainer and a new cotter pin.
(4) Install the brake rotor, caliper anchor, caliper
and ABS wheel speed sensor, refer to Group 5
Brakes.
(5) Install the wheel and tire assembly.
WHEEL MOUNTING STUDS
CAUTION: Do not use a hammer to remove wheel
studs.
REMOVAL
(1) Raise and support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove brake caliper and rotor, refer to Group
5 Brakes for procedure.
(4) Remove stud from hub with Remover C-4150A
(Fig. 17).
INSTALLATION
(1) Install new stud into hub flange.
(2) Install three washers onto stud, then install
lug nut with the flat side of the nut against the
washers.
(3) Tighten lug nut until the stud is pulled into
the hub flange. Verify that the stud is properly
seated into the flange.
Fig. 14 Track Bar Frame Rail Bracket
Fig. 15 Track Bar Axle Bracket
Fig. 16 Hub Bearing & Knuckle

(4) Remove lug nut and washers.
(5) Install the brake rotor and caliper, refer to
Group 5 Brakes for procedure.
(6) Install wheel and tire assembly, use new lug
nut on stud or studs that were replaced.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Shock Absorber
Upper Nut . . . . . . . . . . . . . . . . 35 N·m (26 ft. lbs.)
Lower Nuts . . . . . . . . . . . . . . 28 N·m (250 in. lbs.)
Suspension Arm Upper
Axle Bracket Nut . . . . . . . . . . 61 N·m (45 ft. lbs.)
Frame Bracket Bolt . . . . . . . . . 61 N·m (45 ft. lbs.)
Suspension Arm Lower
Axle Bracket Nut . . . . . . . . 176 N·m (130 ft. lbs.)
Frame Bracket Bolt . . . . . . . 176 N·m (130 ft. lbs.)
Stabilizer Bar
Retainer Bolts . . . . . . . . . . . . . 92 N·m (68 ft. lbs.)
Link Upper Nut . . . . . . . . . . 106 N·m (78 ft. lbs.)
Link Lower Nut . . . . . . . . . . 106 N·m (78 ft. lbs.)
Track Bar
Frame Bracket Nut . . . . . . . . 108 N·m (80 ft. lbs.)
Axle Bracket Bolt . . . . . . . . . 100 N·m (74 ft. lbs.)
Hub Bearing
Knuckle Bolts . . . . . . . . . . . . 102 N·m (75 ft. lbs.)
SPECIAL TOOLS
FRONT SUSPENSION
Remover/Installer Suspension Bushing 7932
Spacer 8279
Nut, Long 7603
Bolt, Special 7604
Fig. 17 Wheel Stud Removal
TSB 26-10-98 October, 1998

Remover C-4150A
Remover/Installer 6289
Reciever 6761
Installer 6752
SPECIAL TOOLS (Continued)

REAR SUSPENSION
INDEX
page page
COIL SPRINGS AND ISOLATORS . . . . . . . . . . . 15
JOUNCE BUMPERS . . . . . . . . . . . . . . . . . . . . . . 15
LOWER SUSPENSION ARMS
AND BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . 16
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . 15
SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . . 15
STABILIZER BAR AND LINKS . . . . . . . . . . . . . . . 16
UPPER SUSPENSION ARM, BUSHINGS,
AND BALL JOINT . . . . . . . . . . . . . . . . . . . . . . 16
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . 17
BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
COIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . 18
SERVICE WARNINGS AND CAUTIONS . . . . . . . 17
SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . 17
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 20
UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . 19
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIAL TOOLS
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . 21
REAR SUSPENSION
The rear suspension (Fig. 1) is comprised of :
• Drive axle
• Shock absorbers
• Coil springs
• Lower suspension arms
• Upper suspension arm
• Stabilizer bar
CAUTION: Suspension components with rubber/
urethane bushings should be tightened with the
vehicle at normal ride height. It is important to have
the springs supporting the weight of the vehicle
when the fasteners are torqued. This will maintain
vehicle ride comfort and prevent premature bushing
wear.
SHOCK ABSORBERS
DESCRIPTION
The top of the shock absorbers are bolted to the
body. The bottom of the shocks are bolted to the axle
brackets. The standard shocks have conventional
twin tube construction and are low pressure gas
charged. Gas charging prevents cavitation during
rough road operation. Up-Country shocks are mono
tube design and are high pressure gas charged.
OPERATION
The shock absorbers dampen jounce and rebound
motion of the vehicle over various road conditions
and limit suspension rebound travel.
JOUNCE BUMPERS
DESCRIPTION
The jounce bumpers are mounted inside the coil
spring, between the axle and the frame rail, to minimize
transmission of noise to the passenger compartment.
OPERATION
The jounce bumpers are used to limit suspension
travel in compression.
COIL SPRINGS AND ISOLATORS
DESCRIPTION
The coil springs mount up in the wheelhouse which is
part of the unitized body bracket. A rubber doughnut
isolator is located between the top of the spring and the
body. The bottom of the spring seats on a axle isolator
Fig. 1 Rear Suspension

made of rubber with a steel insert. The isolators provide
road noise isolation.
OPERATION
The coil springs control ride quality and maintain
proper ride height.
LOWER SUSPENSION ARMS AND BUSHINGS
DESCRIPTION
The lower suspension arms are hydroformed steel
and use voided oval bushings at each end of the arm.
OPERATION
The bushings provide isolation from the axle. The
arms mount to the unibody frame rail bracket and
the axle brackets. The arm and bushings provide
location and react to loads.
UPPER SUSPENSION ARM, BUSHINGS, AND
BALL JOINT
DESCRIPTION
The suspension arm uses vertical spool bushings to
isolate road noise. The suspension arm is bolted
through bushings to cage nuts in the body and a ball
joint plate to the top of the differential housing.
OPERATION
The upper suspension arm provides fore/aft and
lateral location of the rear axle. The suspension arm
travel is limited through the use of jounce bumpers
in compression and shock absorbers in rebound.
STABILIZER BAR AND LINKS
Inspect for broken or distorted stabilizer bar bush-
ings, bushing retainers, and worn, damaged, or
squeeking stabilizer bar to frame links. The stabilizer
bar should also be inspected for signs of cracking or
breaking.

REAR SUSPENSION
CONDITION POSSIBLE CAUSES CORRECTION
VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Replace wheel bearings.
2. Loose, worn or bent suspension
components.
2. Inspect, tighten or replace components
as necessary.
VEHICLE PULLS TO ONE
SIDE
1. Weak or broken spring. 1. Replace spring.
3. Tires. 3. Replace tires.
4. Brakes. 4. Repair as necassary.
KNOCKING, RATTLING
OR SQUEAKING
1. Worn shock bushings. 1. Replace shock.
2. Loose shock mounting. 2. Tighten to specifications.
3. Shock valve. 3. Replace shock.
4. Loose upper ball joint. 4. Replace ball joint.
components.
as necessary.
IMPROPER TRACKING 1. Bent track bar. 1. Replace track bar.
components.
as necessary.
3. Bent axle. 3. Replace axle.
SERVICE WARNINGS AND CAUTIONS
SHOCK ABSORBER
REMOVAL
hydraulic jack under the axle to support the axle.
CAUTION: Do not allow the axle to hang from the
upper suspension arm ball joint.
(2) Remove the upper nut and bolt from the frame
bracket (Fig. 2).
(3) Remove the lower nut and bolt from the axle
bracket. Remove the shock absorber.
INSTALLATION
(1) Install the shock absorber in the frame bracket
and install the bolt and nut.
Fig. 2 Shock Absorber

(2) Install the shock absorber in the axle bracket
and install the bolt and nut.
(3) Tighten the upper and lower mounting nuts to
92 N·m (68 ft. lbs.).
COIL SPRING
REMOVAL
hydraulic jack under the axle to support the axle.
(2) Remove the wheel and tire assemblies.
(3) Remove the stabilizer bar link from the stabi-
lizer bar (Fig. 3).
(4) Remove the shock absorber lower bolt from the
axle bracket.
(5) Lower the hydraulic jack and tilt the axle and
remove the coil spring (Fig. 3).
(6) Remove and inspect the upper and lower
spring isolators (Fig. 3).
INSTALLATION
(1) Install the upper isolator.
(2) Install the lower isolator with the isolator loca-
tor nub in the axle pad hole (Fig. 4).
(3) Pull down on the axle and position the coil
spring in the lower isolator.
CAUTION: Ensure the spring is positioned on the
lower isolator with the end of the spring coil
against the isolator spring locator (Fig. 5).
(4) Raise the axle with the hydraulic jack.
(5) Install the shock absorber to the axle bracket
and tighten to specification.
(6) Install the stabilizer bar link to the stabilizer
bar.
(7) Install the wheel and tire assemblies.
(9) Tighten the stabilizer bar links to specification.
LOWER SUSPENSION ARM
REMOVAL
(1) Raise the vehicle and support the rear axle.
(2) Remove the lower suspension arm nut and bolt
from the axle bracket (Fig. 6).
(3) Remove the nut and bolt (Fig. 6) from the
frame rail and remove the lower suspension arm.
INSTALLATION
(1) Position the lower suspension arm in the axle
bracket and frame rail bracket.
NOTE: The end of the arm with the oval bushing
attaches to the axle bracket.
(2) Install the axle bracket bolt and nut finger
tight.
(3) Install the frame rail bracket bolt and nut fin-
ger tight.
Fig. 3 Coil Spring
Fig. 4 Isolator Locator Nub
Fig. 5 Isolator Spring Locator - Typical

(5) With the vehicle on the ground tighten the
lower suspension arm nuts to 177 N·m (130 ft. lbs.).
UPPER SUSPENSION ARM
REMOVAL
(2) Support the rear axle with a hydraulic jack.
(3) Remove the park brake cables and brake hose
from the arm (Fig. 7).
(4) Remove the ball joint nut from the top of the
upper suspension arm (Fig. 8).
(5) Separate ball joint from the arm with Remover
8278 (Fig. 9).
(6) Remove the upper suspension arm mounting
bolts and remove the arm (Fig. 10).
INSTALLATION
(1) Position the upper suspension arm in the
frame rail brackets.
(2) Install the mounting bolts and tighten to 100
N·m (74 ft. lbs.).
(3) Pull the arm down on the ball joint stud and
install a new nut. Tighten the nut to 142 N·m (105
ft. lbs.).
(4) Install the park brake cables and brake hose to
the arm.
BALL JOINT
REMOVAL
(2) Support the rear axle with a hydraulic jack.
(3) Remove the ball joint nut from the top of the
upper suspension arm (Fig. 11).
Fig. 6 Lower Suspension Arm
Fig. 7 Park Brake Cables And Brake Hose
Fig. 8 Ball Joint Nut
Fig. 9 Separate Ball Joint
TSB 26-10-98 October, 1998

(4) Separate ball joint from the arm with Remover
8278 (Fig. 12).
(5) Remove the ball joint mounting bolts (Fig. 13)
from the differential housing.
(6) Remove the ball joint from the differential
housing.
INSTALLATION
(1) Install the ball joint on the differential hous-
ing.
(2) Install the ball joint mounting bolts and
tighten to 136 N·m (100 ft. lbs.).
(3) Raise the rear axle with a hydraulic jack to
align the upper arm with the ball joint.
(4) Pull the arm down on the ball joint stud and
install a new nut. Tighten the nut to 142 N·m (105
ft. lbs.).
STABILIZER BAR
REMOVAL
(2) Remove the stabilizer bar links from stabilizer
bar and frame mount. (Fig. 14).
(3) Remove the stabilizer bar retainer bolts.
(4) Remove the stabilizer bar.
Fig. 10 Upper Suspension Arm Mounting Bolt
Fig. 11 Ball Joint Nut
Fig. 12 Separate Ball Joint
Fig. 13 Ball Joint Mounting Bolts
TSB 26-10-98 October, 1998

INSTALLATION
(1) Position the stabilizer bar on the axle and
install the retainers and bolts. Ensure the bar is cen-
tered with equal spacing on both sides. Tighten the
bolts to 54 N·m (40 ft. lbs.).
(2) Install the links to the stabilizer bar and frame
brackets.
(3) Tighten the nuts at the stabilizer bar to 54
N·m (40 ft. lbs.).
(4) Tighten the nuts at the frame brackets to 92
N·m (68 ft. lbs.).
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Shock Absorber
Upper Nut . . . . . . . . . . . . . . . . 92 N·m (68 ft. lbs.)
Lower Nut . . . . . . . . . . . . . . . . 92 N·m (68 ft. lbs.)
Suspension Arm Upper
Ball Joint Nut . . . . . . . . . . . 142 N·m (105 ft. lbs.)
Frame Bolts . . . . . . . . . . . . . 100 N·m (74 ft. lbs.)
Ball Joint
Plate Bolts . . . . . . . . . . . . . . 136 N·m (100 ft. lbs.)
Suspension Arms Lower
Nuts . . . . . . . . . . . . . . . . . . 177 N·m (130 ft. lbs.)
Stabilizer Bar
Retainer Bolts . . . . . . . . . . . . . 54 N·m (40 ft. lbs.)
Bar Link Nut . . . . . . . . . . . . . 54 N·m (40 ft. lbs.)
Bracket Link Nut . . . . . . . . . . 92 N·m (68 ft. lbs.)
SPECIAL TOOLS
REAR SUSPENSION
Remover 8278
Fig. 14 Rear Stabilizer Bar
TSB 26-10-98 October, 1998

DIFFERENTIAL AND DRIVELINE
CONTENTS
page page
186 FBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
198 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
226 RBA AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 84
PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . . . . . 1
PROPELLER SHAFTS
INDEX
page page
GENERAL INFORMATION
FRONT PROPELLER SHAFT . . . . . . . . . . . . . . . . 2
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PROPELLER SHAFT JOINT ANGLE . . . . . . . . . . . 2
PROPELLER SHAFT JOINTS . . . . . . . . . . . . . . . . 2
PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . . . . 1
RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
UNBALANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE PROCEDURES
DRIVELINE ANGLE MEASUREMENT
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . 5
PROPELLER SHAFT ANGLE MEASUREMENT . . . 5
FRONT PROPELLER SHAFT . . . . . . . . . . . . . . . . 7
REAR PROPELLER SHAFT . . . . . . . . . . . . . . . . . 7
DISASSEMBLY AND ASSEMBLY
SINGLE CARDAN UNIVERSAL JOINT . . . . . . . . . 8
CLEANING AND INSPECTION
SINGLE CARDAN JOINT . . . . . . . . . . . . . . . . . . . 9
ADJUSTMENTS
FRONT PROPELLER SHAFT MEASUREMENT . . 10
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIAL TOOLS
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . 10
GENERAL INFORMATION
PROPELLER SHAFTS
The function of a propeller shaft is to transmit
power from one point to another in a smooth action.
The shaft is designed to send torque through an
angle from the transmission (transfer case on 4WD
vehicles) to the axle (Fig. 1).
The propeller shaft must operate through con-
stantly changing relative angles between the trans-
mission/transfer case and axle. It must also be
capable of changing length while transmitting
torque. The axle rides suspended by springs in a
floating motion. This means the propeller shaft must
be able to change angles when going over various
roads. This is accomplished through universal joints
or Constant Velocity(CV) joints, which permit the
propeller shaft to operate at different angles. A slip
joint or CV joint permit contraction or expansion.
Tubular propeller shafts are balanced by the man-
ufacturer with weights spot welded to the tube.
The propeller shaft is designed and built with the
yoke lugs in line with each other which is called
phasing. This design produces the smoothest running
condition. An out of phase shaft can cause a vibra-
tion.
Before undercoating a vehicle, the propeller
shaft and the U-joints should be covered. This
will prevent the undercoating from causing an
out of balance condition and vibration.
CAUTION: Use exact replacement parts for attach-
ing the propeller shafts. This will ensure safe oper-
ation. The specified torque must always be applied
when tightening the fasteners.
WJ DIFFERENTIAL AND DRIVELINE 3 - 1

FRONT PROPELLER SHAFT
Only one style of front propeller shaft is used on
WJ vehicles. The propeller shaft uses a Constant
Velocity (CV) joint at both the axle and transfer case
end of the propeller shaft. The CV joint at the axle
end contracts and extends (plunges) as necessary to
accomadate the variations in length necessary due to
suspension travel. The CV joint at the transfer case
end of the propeller shaft is fixed. The two CV joints
are connected by a hollow tube shaft. The shaft
length is not adjustable and does vary according to
application.
PROPELLER SHAFT JOINTS
Two different types of propeller shaft joints are
used in WJ vehicles (Fig. 2) and (Fig. 3). Neither of
the joints are servicible. If worn or damaged, they
must be replaced. If a vehicle has a damaged or worn
Constant Velocity (CV) joint, or boot, the propeller
shaft must be replaced.
PROPELLER SHAFT JOINT ANGLE
When two shafts come together at a common joint,
the bend that is formed is called the operating angle.
The larger the angle, the larger the amount of angu-
lar acceleration and deceleration of the joint. This
speeding up and slowing down of the joint must be
cancelled to produce a smooth power flow. This is
done through the phasing of a propeller shaft and
ensuring that the proper propeller shaft joint work-
ing angles are maintained.
A propeller shaft is properly phased when the yoke
ends are in the same plane, or in line. A twisted
shaft will make the yokes out of phase and cause a
noticeable vibration.
Fig. 1 Front & Rear Propeller Shafts
Fig. 2 Single Cardan U-Joint
Fig. 3 Constant Velocity Joint
3 - 2 DIFFERENTIAL AND DRIVELINE WJ
GENERAL INFORMATION (Continued)

Ideally the driveline system should have;
• Angles that are equal or opposite within 1
degree of each other.
• Have a 3 degree maximum operating angle.
• Have at least a 1/2 degree continuous operating
(propeller shaft) angle.
Engine speed (rpm) is the main factor in determin-
ing the maximum allowable operating angle. As a
guide to the maximum normal operating angles refer
to (Fig. 4).
LUBRICATION
The factory installed universal joints are lubricated
for the life of the vehicle and do not need lubrication.
All universal joints should be inspected for leakage
and damage each time the vehicle is serviced. If seal
leakage or damage exists, the universal joint should
be replaced.
The Constant Velocity joint should also be
inspected each time the vehicle is serviced. The CV
joint boot is designed to last the life of the vehicle
and to keep the joint lubricated. If grease leakage or
boot damage is found, the propeller shaft must be
replaced.
PRECAUTIONS
Use the exact replacement parts when installing
the propeller shafts. The use of the correct replace-
ment parts helps to ensure safe operation. All fasten-
ers must be torqued to the specified values for safe
operation .
Also make alignment reference marks (Fig. 5) on
the propeller shaft yoke and axle, or transmission,
yoke prior to servicing. This helps to eliminate possi-
ble vibration.
CAUTION: Do not allow the propeller shaft to drop
or hang from any propeller shaft joint during
removal. Attach the propeller shaft to the vehicle
underside with wire to prevent damage to the joints.
CAUTION: It is very important to protect the exter-
nal machined surface of the slip yoke from damage
during and after propeller shaft removal. If the yoke
is damaged, the transmission extension seal may
be damaged and therefore cause a leak.
VIBRATION
Tires that are out-of-round, or wheels that are
unbalanced, will cause a low frequency vibration.
Refer to Group 22, Tires and Wheels, for additional
information.
Driveline vibration can also result from loose or
damaged engine mounts. Refer to Group 9, Engines,
for additional information.
Propeller shaft vibration increases as the vehicle
speed is increased. A vibration that occurs within a
specific speed range is not usually caused by a pro-
peller shaft being unbalanced. Defective universal
joints, or an incorrect propeller shaft angle, are usu-
ally the cause of such a vibration.
UNBALANCE
NOTE: Removing and re-indexing the propeller
shaft 180° relative to the yoke may eliminate some
vibrations.
If propeller shaft is suspected of being unbalanced,
it can be verified with the following procedure:
(1) Raise the vehicle.
(2) Clean all the foreign material from the propel-
ler shaft and the universal joints.
Fig. 4 Maximum Angles And Engine Speed
Fig. 5 Reference Marks on Yokes
GENERAL INFORMATION (Continued)

(3) Inspect the propeller shaft for missing balance
weights, broken welds, and bent areas. If the pro-
peller shaft is bent, it must be replaced.
(4) Inspect the universal joints to ensure that they
are not worn, are properly installed, and are cor-
rectly aligned with the shaft.
(5) Check the universal joint clamp screws torque.
(6) Remove the wheels and tires. Install the wheel
lug nuts to retain the brake drums or rotors.
(7) Mark and number the shaft six inches from the
yoke end at four positions 90° apart.
(8) Run and accelerate the vehicle until vibration
occurs. Note the intensity and speed the vibration
occurred. Stop the engine.
(9) Install a screw clamp at position 1 (Fig. 6).
(10) Start the engine and re-check for vibration. If
there is little or no change in vibration, move the
clamp to one of the other three positions. Repeat the
vibration test.
(11) If there is no difference in vibration at the
other positions, the source of the vibration may not
be propeller shaft.
(12) If the vibration decreased, install a second
clamp (Fig. 7) and repeat the test.
DRIVELINE VIBRATION
Fig. 6 Clamp Screw At Position 1
Fig. 7 Two Clamp Screws At The Same Position
DIAGNOSIS AND TESTING (Continued)

(13) If the additional clamp causes an additional
vibration, separate the clamps (1/4 inch above and
below the mark). Repeat the vibration test (Fig. 8).
(14) Increase distance between the clamp screws
and repeat the test until the amount of vibration is
at the lowest level. Bend the slack end of the clamps
so the screws will not loosen.
(15) If the vibration remains unacceptable, apply
the same steps to the front end of the propeller shaft.
(16) Install the wheel and tires. Lower the vehicle.
RUNOUT
(1) Remove dirt, rust, paint, and undercoating
from the propeller shaft surface where the dial indi-
cator will contact the shaft.
(2) The dial indicator must be installed perpendic-
ular to the shaft surface.
(3) Measure runout at the center and ends of the
shaft sufficiently far away from weld areas to ensure
that the effects of the weld process will not enter into
the measurements.
(4) Refer to Runout Specifications chart.
(5) If the propeller shaft runout is out of specifica-
tion, remove the propeller shaft, index the shaft 180°,
and re-install the propeller shaft. Measure shaft
runout again.
(6) If the propeller shaft runout is now within
specifications, mark the shaft and yokes for proper
orientation.
(7) If the propeller shaft runout is not within spec-
ifications, verify that the runout of the transmission/
transfer case and axle are within specifications.
Correct as necessary and re-measure propeller shaft
runout.
(8) Replace the propeller shaft if the runout still
exceeds the limits.
SERVICE PROCEDURES
DRIVELINE ANGLE MEASUREMENT
PREPARATION
Before measuring universal joint angles, the fol-
lowing must be done;
• Inflate all tires to correct pressure.
• Check the angles in the same loaded or
unloaded condition as when the vibration occurred.
Propeller shaft angles change according to the
amount of load in the vehicle.
• Check the condition of all suspension compo-
nents and verify all fasteners are torqued to specifi-
cations.
• Check the condition of the engine and transmis-
sion mounts and verify all fasteners are torqued to
specifications.
PROPELLER SHAFT ANGLE MEASUREMENT
To accurately check driveline alignment, raise and
support the vehicle at the axles as level as possible.
Allow the wheels and propeller shaft to turn. Remove
any external bearing snap rings, if equipped, from
universal joint so that the inclinometer base sits flat.
The same basic procedure applies to both the front
propeller shafts and the rear propeller shaft. To
obtain the front (output) angle on the CV front pro-
peller shaft, the inclinometer is placed on the
machined ring of the pinion flange. To obtain the pro-
peller shaft angle measurement on the CV front pro-
peller shaft, the inclinometer is placed on the
propeller shaft tube.
(1) Rotate the shaft until transmission/transfer
case output yoke bearing cap is facing downward, if
necessary.
Always make measurements from front to
rear.
Fig. 8 Clamp Screws Separated
RUNOUT SPECIFICATIONS
Front of Shaft 0.020 in. (0.50 mm)
Center of Shaft 0.025 in. (0.63 mm)
Rear of Shaft 0.020 in. (0.50 mm)
Measure front/rear runout approximately 3 inches (76
mm) from the weld seam at each end of the shaft
tube for tube lengths over 30 inches. For tube lengths
under 30 inches, the maximum allowed runout is
0.020 in. (0.50 mm) for the full length of the tube.
DIAGNOSIS AND TESTING (Continued)

(2) Place Inclinometer on yoke bearing cap, or the
pinion flange ring, (A) parallel to the shaft (Fig. 9).
Center bubble in sight glass and record measure-
ment.
This measurement will give you the transmis-
sion or Output Yoke Angle (A).
(3) Rotate propeller shaft 90 degrees and place
Inclinometer on yoke bearing cap, or propeller shaft
tube on CV propeller shaft, parallel to the shaft (Fig.
10). Center bubble in sight glass and record measure-
ment. This measurement can also be taken at the
rear end of the shaft.
This measurement will give you the propeller
shaft angle (C).
(4) Subtract smaller figure from larger (C minus
A) to obtain transmission output operating angle.
(5) Rotate propeller shaft 90 degrees and place
Inclinometer on pinion yoke bearing cap parallel to
the shaft (Fig. 11). Center bubble in sight glass and
record measurement.
This measurement will give you the pinion
shaft or input yoke angle (B).
(6) Subtract smaller figure from larger (C minus
B) to obtain axle Input Operating Angle.
Refer to rules given below and the example in (Fig.
12) for additional information.
• Good cancellation of U–joint operating angles
(within 1°).
• Operating angles less than 3°.
• At least 1/2 of one degree continuous operating
(propeller shaft) angle.
Fig. 9 Front (Output) Angle Measurement (A)
Fig. 10 Propeller Shaft Angle Measurement (C)
Fig. 11 Rear (Input) Angle Measurement (B)

FRONT PROPELLER SHAFT
NOTE: Different length propeller shafts are used for
different drivetrain applications. Ensure that the
correct propeller shaft is used.
REMOVAL
(1) Raise and support vehicle on safety stands.
(2) Shift the transmission and transfer case, if nec-
essary, into the Neutral position.
(3) Using a suitable marker, mark a line across
the companion flange at the transfer case and CV
joint at the rear of the front propeller shaft for
installation reference.
(4) Mark a line across the CV joint and the pinion
companion flange for installation reference.
(5) Remove the bolts holding the front CV joint to
the pinion companion flange.
(6) Remove the bolts holding the rear CV joint to
the transfer case companion flange.
(7) Separate the rear CV joint from the transfer
case companion flange.
(8) Push rear of propeller shaft upward to clear
transfer case companion flange.
(9) Separate front CV joint from front axle.
(10) Separate propeller shaft from vehicle.
INSTALLATION
(1) Position front propeller shaft under vehicle
with rear CV joint over the transfer case companion
flange.
(2) Place front CV joint into the axle pinion com-
panion flange. CV joint should rotate freely in the
pinion flange.
(3) Align mark on the transfer case companion
flange to the mark on the CV joint at the rear of the
front propeller.
(4) Loosely install bolts to hold CV joint to transfer
case companion flange.
(5) Align mark on front CV joint to the mark on
the axle pinion companion flange.
(6) Install bolts to hold front CV joint to the axle
pinion companion flange. Tighten bolts to 32 N·m
(23.5 ft. lbs.).
(7) Tighten bolts to hold rear CV joint to the trans-
fer case companion flange to 32 N·m (23.5 ft. lbs.).
(8) Lower vehicle and road test to verify repair.
REAR PROPELLER SHAFT
REMOVAL
(1) Raise and support vehicle on safety stands.
Fig. 12 Universal Joint Angle Example

(2) Shift the transmission and transfer case, if nec-
essary, to their Neutral positions.
(3) Using a suitable marker, mark a line across
the axle pinion yoke and the propeller shaft yoke for
installation reference.
(4) Remove the bolts holding the universal joint
clamps to the pinion yoke.
(5) Slide the slip yoke off of the transmission, or
transfer case, output shaft and remove the propeller
shaft (Fig. 13).
INSTALLATION
(1) Slide the slip yoke on the transmission, or
transfer case, output shaft.
(2) Align the installation reference marks made on
the propeller shaft and pinion yoke.
(3) Position universal joint into pinion yoke.
(4) Install the universal joint clamp and clamp
bolts to the pinion yoke. Tighten bolts to 19 N·m (14
ft. lbs.).
(5) Lower the vehicle.
DISASSEMBLY AND ASSEMBLY
SINGLE CARDAN UNIVERSAL JOINT
DISASSEMBLY
Individual components of cardan universal joints
are not serviceable. If worn or leaking, they must be
replaced as an assembly.
(1) Remove the propeller shaft.
(2) Using a soft drift, tap the outside of the bear-
ing cap assembly to loosen snap ring.
(3) Remove snap rings from both sides of yoke
(Fig. 14).
(4) Set the yoke in an arbor press or vise with a
socket whose inside diameter is large enough to
receive the bearing cap positioned beneath the yoke.
(5) Position the yoke with the grease fitting, if
equipped, pointing up.
(6) Place a socket with an outside diameter
smaller than the upper bearing cap on the upper
bearing cap and press the cap through the yoke to
release the lower bearing cap (Fig. 15).
Fig. 13 Rear Propeller Shaft
Fig. 14 Remove Snap Ring
Fig. 15 Press Out Bearing

1999 Jeep Grand Cherokee WJ Service Manual.pdf

1999 Jeep Grand Cherokee WJ Service Manual.pdf

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