Jeep Wrangler 1999 Electronic Service Manual
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Jeep Wrangler 1999 Electronic Service Manual

Jeep Wrangler 1999 Electronic Service Manual

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Summary of Contents for Jeep Wrangler 1999

  • Page 2: Table Of Contents

    VEHICLE IDENTIFICATION NUMBER DECODING CHART POSITION INTERPRETATION CODE = DESCRIPTION Country of Origin 1 = United States Make J = Jeep Vehicle Type 4 = MPV Gross Vehicle Weight Rating E = 3001-4000 lbs. F = 4001-5000 lbs. Vehicle Line...

  • Page 3: General Information

    INTRODUCTION GENERAL INFORMATION (Continued) Fig. 1 Vehicle Safety Certification Label—Typical VEHICLE SAFETY CERTIFICATION LABEL 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: •...
  • Page 4 INTRODUCTION GENERAL INFORMATION (Continued) BODY CODE PLATE—LINE 3 DIGIT 19 Open Space DIGITS 1 THROUGH 12 DIGITS 20, 21, AND 22 Vehicle Order Number Engine Code • EPE = 2.5 L 4 cyl. MPI Gasoline DIGITS 13, 14, AND 15 •...

  • Page 5: Fastener Identification

    INTRODUCTION GENERAL INFORMATION (Continued) INTERNATIONAL CONTROL AND DISPLAY SYMBOLS Fig. 4 FASTENER IDENTIFICATION 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 FASTENER IDENTIFICATION imprinted with a single-digit strength class on the nut face.
  • Page 6 INTRODUCTION GENERAL INFORMATION (Continued) FASTENER IDENTIFICATION...
  • Page 7 INTRODUCTION GENERAL INFORMATION (Continued) FASTENER STRENGTH...

  • Page 8: Metric System

    INTRODUCTION GENERAL INFORMATION (Continued) THREADED HOLE REPAIR The following chart will assist in converting metric units to equivalent English and SAE units, or vice Most stripped threaded holes can be repaired using versa. a Helicoil . Follow the manufactures recommenda- Refer to the Conversion Chart to convert torque tions for application and repair procedures.
  • Page 9 INTRODUCTION GENERAL INFORMATION (Continued) METRIC CONVERSION...

  • Page 10: Torque References

    INTRODUCTION GENERAL INFORMATION (Continued) TORQUE REFERENCES individual torque charts. 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 TORQUE SPECIFICATIONS...

  • Page 12: Vehicle Identification Number

    VEHICLE IDENTIFICATION NUMBER DECODING CHART POSITION INTERPRETATION CODE = DESCRIPTION Country of Origin 1 = United States Make J = Jeep Vehicle Type 4 = MPV Gross Vehicle Weight Rating E = 3001-4000 lbs. F = 4001-5000 lbs. Vehicle Line...

  • Page 13: Vehicle Safety Certification Label

    INTRODUCTION GENERAL INFORMATION (Continued) Fig. 1 Vehicle Safety Certification Label—Typical VEHICLE SAFETY CERTIFICATION LABEL 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: •...
  • Page 14 INTRODUCTION GENERAL INFORMATION (Continued) BODY CODE PLATE—LINE 3 DIGITS 10 THROUGH 13 Secondary Paint DIGITS 1 THROUGH 12 DIGIT 14 Vehicle Order Number Open Space DIGITS 13, 14, AND 15 DIGITS 15 THROUGH 18 Roof • VJN = Soft Top White Interior Trim Code •...
  • Page 15 INTRODUCTION GENERAL INFORMATION (Continued) INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS INTERNATIONAL VEHICLE CONTROL AND 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.
  • Page 16 June 7, 2002 June 7, 2002...
  • Page 17 June 7, 2002 June 7, 2002...
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  • Page 21 June 7, 2002 June 7, 2002...
  • Page 22 June 7, 2002 June 7, 2002...
  • Page 23 GROUP 2 - Front Suspension & Drive Illustration Title Group-Fig. No. Front Suspension Suspension,Front,Springs,Control Arms,Shocks and Track Bar 1997 TJ ..... . Fig.
  • Page 24 Track Bar to Frame, Mounting Track Bar to Frame, Mounting PIN, Cotter, M3.2x36, (NOT SERVICED) BAR, Track 5208 8432 5208 8430 NUT, Hex Flange Lock, M10x1.5 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 25 Lower Control Arm to Axle, Mounting Lower Control Arm to Axle, Mounting 5208 8654 ARM, Control, with Bushing, Lower 5208 8433 BUSHING, Control Arm, Lower Control Arm to Frame, Lower JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 26 5200 5917 BRACKET, Spring, Coil Spring Retainer, Mounting 5208 7711 ARM, Control, with Bushing, Upper 1150 6007 NUT, Hex Flange, M10x1.5, Upper Control Arm to Axle, Mounting JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 27 NUT, Hex, M14-2, Lower Control Arm to Axle, Mounting 5208 8654 ARM, Control, with Bushing, Lower 5208 8433 BUSHING, Control Arm, Lower Control Arm to Frame, Lower JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 28 BRACKET, Spring, Coil Spring Retainer, Mounting 5208 7711 ARM, Control, with Bushing, Upper 1150 6007 NUT, Hex Flange, M10x1.5, UCA to Axle, Mounting BOLT AND RETAINER, Hex Head, M10x1.50x75.00 , (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 29 WASHER, M14, LCA to Axle, Mounting 6503 841 NUT, Hex, M14-2, LCA to Axle, Mounting 5208 8654 ARM, Control, with Bushing, Lower 5208 8433 BUSHING, Control Arm, LCA to Frame JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 30 SCREW, Truss Head, M12x1.75x70 6502 930 5208 8378 BUSHING, Sway Bar 5203 7710 RETAINER, Sway Bar 6102 037AA SCREW AND WASHER, Hex Head, M10x1.50x35 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 31 6505 465AA SCREW, Truss Head, M12x1.75x70 5208 8378 BUSHING, Sway Bar 5203 7710 RETAINER, Sway Bar 6102 037AA SCREW AND WASHER, Hex Head, M10x1.50x35 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 32 6505 465AA SCREW, Truss Head, M12x1.75x70 5208 8378 BUSHING, Sway Bar 5203 7710 RETAINER, Sway Bar 6102 037AA SCREW AND WASHER, Hex Head, M10x1.50x35 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 33 Right or Left Right or Left SEAL, Axle Drive Shaft J812 1781 Right or Left Right or Left SNAP RING, Front Axle Shaft 4137 739 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 34 SEAL, Axle Drive Shaft J812 1781 Right or Left Right or Left SNAP RING, Front Axle Shaft 4137 739 Right or Left Right or Left JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 35 SEAL, Axle Drive Shaft 4874 477 Right or Left Right or Left SNAP RING, Front Axle Shaft 4137 739 Right or Left Right or Left JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 36 PIN, Cotter, M4x40.00 1101 0069 BALL JOINT KIT, Knuckle 8350 0202 BOLT, Differential Cover 2954 031 PLUG, Differential Cover J400 4751 COVER, Differential JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 37 HOUSING, Axle 4864 840 4864 904 BOLT, Differential 8350 1515 5602 7727 SENSOR, Anti-Lock Brakes 8350 4920 BOLT JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 38 PIN, Cotter, M4x40.00 1101 0069 BALL JOINT KIT, Knuckle 8350 0202 BOLT, Differential Cover 2954 031 PLUG, Differential Cover J400 4751 COVER, Differential JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 39 HOUSING, Axle 4864 840 4864 904 BOLT, Differential 4897 482AB 5602 7727 SENSOR, Anti-Lock Brakes 8350 4920 BOLT JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 40 PIN, Cotter, M4x40.00 1101 0069 BALL JOINT KIT, Knuckle 8350 0202 BOLT, Differential Cover 2954 031 PLUG, Differential Cover J400 4751 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 41 HOUSING, Axle 4864 840 4864 904 BOLT, Differential 4897 482AB 5602 7727 SENSOR, Anti-Lock Brakes 8350 4920 BOLT JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 42 4864 910 [DMF] with Tag 52099439 4864 852 [DMM] with Tag 52099440,52099453 4882 337 [DME] with Tag 52099450 4882 155 [DMM] with Tag 52099454 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 43 4864 910 [DMF] with Tag# 52099226AB 4864 852 [DMM] with Tag# 52099198AB,52099227AB 4882 337 [DME] with Tag# 52099450AC 4882 155 [DMM] with Tag# 52099454AC JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 44 4864 910 [DMF] with Tag# 52099226AB 4864 852 [DMM] with Tag# 52099198AB,52099227AB 4882 337 [DME] with Tag# 52099450AC 4882 155 [DMM] with Tag# 52099454AC JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 45 [DMM] 4864 843 [DME] BOLT KIT 4720 891 Consists of 10 5252503 Screws Consists of 10 5252503 Screws SCREW, Drive Gear JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 46 [DMD,DMM] 5252 590 [DME,DMF] GEAR KIT, Center Differential 5252 591 PIN, Differential Shaft 1791 563 5010 884AA SEALANT, RTV JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 47 [DME] BOLT KIT 4720 891 Consists of 10 5252503 Screws Consists of 10 5252503 Screws SCREW, Drive Gear 5252 503 BEARING, Differential JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 48 [DME] 5252 582 [DMM] GEAR KIT, Center Differential 5252 591 PIN, Differential Shaft 1791 563 5010 884AA SEALANT, RTV JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 49 4864 843 [DME] 4864 853 [DMM] BOLT KIT 4720 891 Consists of 10-5252503 Screws Consists of 10-5252503 Screws SCREW, Drive Gear JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 50 5252 582 [DMM] GEAR KIT, Center Differential 5252 591 PIN, Differential Shaft 1791 563 5010 884AA EP0, SEALANT, RTV JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 51 GROUP 3 - Rear Axle Illustration Title Group-Fig. No. Rear Axle Axle Assembly, Rear 1997 TJ ........... . Fig.

  • Page 52: Figure

    [DRK,DME] Tagged 52111751AB After 11-13-97 4882 908 [DRK,DMF] Tagged 52111752 4882 907 [DRK,DMM] Tagged 52111750 Up to 11-13-97 4897 290AA [DRK,DMM] Tagged 52111750AB After 11-13-97 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...

  • Page 53: Figure

    [DRJ,DMM,DSA] Tag 52111764AB AXLE, Service Rear 5003 375AA [DRK,DME,DSA] Tag 52111032AA 4897 291AA [DRK,DME,DSA] Tag 52111751AB 4897 290AA [DRK,DMM,DSA] Tag 52111750AB JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 54 [DRJ,DMM,DSA] Tag 52111764AB AXLE, Service Rear 5003 375AA [DRK,DME,DSA] Tag 52111032AA 4897 291AA [DRK,DME,DSA] Tag 52111751AB 4897 290AA [DRK,DMM,DSA] Tag 52111750AB JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...

  • Page 55: J812

    5252 493 COVER, Differential J400 6708 SCREW, Pan Head, .312-18x.56, Differential Cover, Mounting 5252 504 PLUG, Differential Cover 5010 884AA SEALANT, RTV JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...

  • Page 56: J813

    5252 493 COVER, Differential J400 6708 SCREW, Pan Head, .312-18x.56, Differential Cover, Mounting 5252 504 PLUG, Differential Cover 5010 884AA SEALANT, RTV JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...

  • Page 57: June

    5252 493 COVER, Differential J400 6708 SCREW, Pan Head, .312-18x.56, Differential Cover, Mounting 5252 504 PLUG, Differential Cover 5010 884AA SEALANT, RTV JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...

  • Page 58: June

    SCREW, Pan Head, .312-18x.56 J400 6708 Differential Cover, Mounting Differential Cover, Mounting PLUG, Differential Cover 5252 504 5010 884AA SEALANT, RTV JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 59 SCREW, Pan Head, .312-18x.56 J400 6708 Differential Cover, Mounting Differential Cover, Mounting PLUG, Differential Cover 5252 504 5010 884AA SEALANT, RTV JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 60 SCREW, Pan Head, .312-18x.56 J400 6708 Differential Cover, Mounting Differential Cover, Mounting PLUG, Differential Cover 5252 504 5010 884AA SEALANT, RTV JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 61 GEAR KIT, Center Differential, without [DSA] J812 0832 WASHER, Differential Side Gear, without [DSA] J812 0831 WASHER, Flat, with or without [DSA] Pinion Thrust 5252 502 PIN, Differential Shaft, with or without [DSA] JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 62 GEAR KIT, Center Differential, without [DSA] J812 0832 WASHER, Differential Side Gear, without [DSA] J812 0831 WASHER, Flat, with or without [DSA] Pinion Thrust 5252 502 PIN, Differential Shaft, with or without [DSA] JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 63 GEAR KIT, Center Differential, without [DSA] J812 0832 WASHER, Differential Side Gear, without [DSA] J812 0831 WASHER, Flat, with or without [DSA] Pinion Thrust 5252 502 PIN, Differential Shaft, with or without [DSA] JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 64 Consists of 2 Bearings and 2 Cups Consists of 2 Bearings and 2 Cups SHIM KIT, Differential J812 9222 SCREW, Drive Gear 5252 503 Ring Gear, Mounting JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 65 J099 4345 GEAR KIT, Center Differential 8350 5432 WASHER, Pinion Thrust 1791 561 SHAFT, Differential 8350 3069 PIN, Differential Shaft 1791 563 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 66 Consists of 2 Bearings and 2 Cups SHIM KIT, Differential J812 9222 SCREW, Drive Gear 5252 503 Ring Gear, Mounting Ring Gear, Mounting CASE, Differential JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 67 J099 4345 GEAR KIT, Center Differential 8350 5432 WASHER, Pinion Thrust 1791 561 SHAFT, Differential 8350 3069 PIN, Differential Shaft 5252 502 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 68 Consists of 2 Bearings and 2 Cups SHIM KIT, Differential J812 9222 SCREW, Drive Gear 5252 503 Ring Gear, Mounting Ring Gear, Mounting CASE, Differential JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 69 J099 4345 GEAR KIT, Center Differential 8350 5432 WASHER, Pinion Thrust 1791 561 SHAFT, Differential 8350 3069 PIN, Differential Shaft 5252 502 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 70 SHAFT, Axle 4713 192 Right 4713 193 Left 5252 505 RETAINER, Axle Shaft, Right or Left 8350 3053 STUD, Hub, Wheel JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 71 SHAFT, Axle 4713 192 Right 4713 193 Left 5252 505 RETAINER, Axle Shaft, Right or Left 8350 3053 STUD, Hub, Wheel JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 72 SHAFT, Axle 4713 192 Right 4713 193 Left 5252 505 RETAINER, Axle Shaft, Right or Left 5011 312AA STUD, Hub, Wheel JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 73 RETAINER, Axle Shaft Seal 5010 811AA SEAL, Axle Drive Shaft 8350 3063 BEARING, Axle 8350 3064 RING, Axle Shaft 8350 3077 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 74 RETAINER, Axle Shaft Seal 5010 811AA SEAL, Axle Drive Shaft 8350 3063 BEARING, Axle 8350 3064 RING, Axle Shaft 8350 3077 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 75 RETAINER, Axle Shaft Seal 5010 811AA SEAL, Axle Drive Shaft 8350 3063 BEARING, Axle 8350 3064 RING, Axle Shaft 8350 3077 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 76 GROUP 4 - Parking Brake Illustration Title Group-Fig. No. Parking Brake Lever and Cables Parking Brake Lever and Cables 1997 TJ ..........Fig.
  • Page 77 Left, Rear Left, Rear BRACKET, Parking Lever 5212 8191 Mini Console 5212 8204 Full Console 6101 695 NUT, Hex Flange Lock, M8x1.25 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 78 CABLE, Parking Brake 5200 8363 BRACKET, Parking Lever 5212 8191 Mini Console 5212 8204 Full Console 6101 695 NUT, Hex Flange Lock, M8x1.25 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 79 CABLE, Parking Brake 5200 8363 BRACKET, Parking Lever 5212 8191 Mini Console 5212 8204 Full Console 6101 695 NUT, Hex Flange Lock, M8x1.25 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 80 GROUP 5 - Service Brakes Illustration Title Group-Fig. No. Front Brakes Front Brakes 1997 TJ ............Fig.
  • Page 81 4778 058AB 4778 058AC BOOT AND SEAL, Disc Brake J813 3852 BUSHING, Disc Brake Caliper 4383 471 SLEEVE, Disc Brake Caliper 4423 573 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 82 Left 5252 984 Right 5252 985 Left SCREW, Bleeder J320 3313 CAP, Bleeder 4238 717 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 83 PAD KIT, Front Disc Brake 4883 344AC BOOT AND SEAL, Disc Brake J813 3852 BUSHING, Disc Brake Caliper 4383 471 SLEEVE, Disc Brake Caliper 4423 573 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 84 Left 5252 984 Right 5252 985 Left SCREW, Bleeder J320 3313 CAP, Bleeder 4238 717 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 85 RETAINER, Hub Nut J420 0097 WASHER, Wave 4740 749 PAD KIT, Front Disc Brake 4883 344AC BOOT AND SEAL, Disc Brake J813 3852 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 86 Left 5252 984 Right 5252 985 Left SCREW, Bleeder J320 3313 CAP, Bleeder 4238 717 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 87 4049 681 REPAIR KIT, Wheel Cylinder 5252 630 SPRING, Parking Brake Strut, Purchase Strut, (NOT SERVICED) STRUT, Parking Brake 4713 590 WASHER, Adjuster Button JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 88 2944 580 Right 2944 581 Left SPRING, Brake Shoe Hold Down 4313 062 LEVER, Park Brake 4313 810 Right JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 89 SCREW, Brake Adjusting 4423 898 Right 4423 899 Left 4423 898 Right 4423 899 Left JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 90 4049 681 REPAIR KIT, Wheel Cylinder 5252 630 SPRING, Parking Brake Strut, Purchase Strut, (NOT SERVICED) STRUT, Parking Brake 4713 590 WASHER, Adjuster Button JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 91 2944 580 Right 2944 581 Left SPRING, Brake Shoe Hold Down 4313 062 LEVER, Park Brake 4313 810 Right JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 92 SCREW, Brake Adjusting 4423 898 Right 4423 899 Left 4423 898 Right 4423 899 Left JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 93 4049 681 REPAIR KIT, Wheel Cylinder 5252 630 SPRING, Parking Brake Strut, Purchase Strut, (NOT SERVICED) STRUT, Parking Brake 4713 590 WASHER, Adjuster Button JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 94 2944 580 Right 2944 581 Left SPRING, Brake Shoe Hold Down 4313 062 LEVER, Park Brake 4313 810 Right JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 95 SCREW, Brake Adjusting 4423 898 Right 4423 899 Left 4423 898 Right 4423 899 Left JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 96 2448 770 CLAMP, Hose HOSE, Brake Booster 5212 8229 [EP0] 3879 277 [ER0] 52008 715AB [EP0] JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 97 HOSE, Brake Booster 52008 715AB [EP0] 52128 389AA [ER0] 3879 277 [ER0] 5212 8229 [EP0] JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 98 HOSE, Brake Booster 5212 8229 [EP0] 3879 277 [ER0] 52008 715AB [EP0] 52128 389AA [ER0] JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 99 PIN, Master Cylinder Reservoir, Mounting J400 3909 NUT, Hex Flange With Serration, Master Cylinder to Brake Booster Stud, Mounting 3420 1711 NUT, Hex Flange, M8x1.25, Combination Valve Bracket to Master Cylinder Stud, Mounting JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 100 PIN, Master Cylinder Reservoir, Mounting J400 3909 NUT, Hex Flange With Serration, Master Cylinder to Brake Booster Stud, Mounting 3420 1711 NUT, Hex Flange, M8x1.25, Combination Valve Bracket to Master Cylinder Stud, Mounting JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 101 PIN, Master Cylinder Reservoir, Mounting J400 3909 NUT, Hex Flange With Serration, Master Cylinder to Brake Booster Stud, Mounting 3420 1711 NUT, Hex Flange, M8x1.25, Combination Valve Bracket to Master Cylinder Stud, Mounting JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 102 BRACKET, Brake Control Unit BRACKET, ABS Sensor 5517 6141 HCU Mounting Tray 5517 6142 HCU Mounting Tray 3420 1888 SCREW, Hex Head, HCU Bracket to Tray, Mounting JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 103 BRACKET, Brake Control Unit BRACKET, ABS Sensor 5517 6141 HCU Mounting Tray 5517 6142 HCU Mounting Tray 3420 1888 SCREW, Hex Head, HCU Bracket to Tray, Mounting JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 104 BRACKET, Brake Control Unit BRACKET, ABS Sensor 5517 6141 HCU Mounting Tray 5517 6142 HCU Mounting Tray 3420 1888 SCREW, Hex Head, HCU Bracket to Tray, Mounting JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 105 SCREW, Brake Tee, .437-20x2.07, Rear Axle Vent and Hose Mounting 5212 7970 BRACKET, Brake Valve, Brake Valve To Master Cylinder 5200 8385 TUBE, Brake, Combo Valve to Rear Brake Hose JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 106 HOSE, Brake, Rear Brake 5200 8549 VALVE, Combination, w/o Bracket , Brake Combination 4137 696 SCREW, Brake Tee, .437-20x2.07 5212 7970 BRACKET, Brake Valve, Brake Valve To Master Cylinder JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 107 5200 8391 HOSE, Brake, Rear Brake 5200 9115 VALVE, Combination 4137 696 SCREW, Brake Tee, .437-20x2.07 5212 7970 BRACKET, Brake Valve, Brake Valve To Master Cylinder JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 108 MODULE, Anti-Lock Brake System, Brake Adaptive 5602 7878 BRACKET, Module, Module Mounting 5212 8175 CLIP, Brake Attaching Tube, 3 Way SCREW, w/Washer M8x1.25x25.00 (Not Serv.), (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 109 HOSE, Brake, Combo Valve To HCU, Secondary 5200 8640 HOSE, Brake, Combo Valve To HCU, Primary 6502 711 BOLT, ABS Sensor, M8x1.25x20.00 6101 695 NUT, Hex Flange Lock, M8x1.25, M8x1.25 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 110 HOSE, Brake, Combo Valve To HCU, Secondary 5200 8640 HOSE, Brake, Combo Valve To HCU, Primary 6502 711 BOLT, ABS Sensor, M8x1.25x20.00 6101 695 NUT, Hex Flange Lock, M8x1.25, M8x1.25 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 111 HOSE, Brake, Combo Valve To HCU, Secondary 5200 8640 HOSE, Brake, Combo Valve To HCU, Primary 6502 711 BOLT, ABS Sensor, M8x1.25x20.00 6101 695 NUT, Hex Flange Lock, M8x1.25 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 112 NUT, U, M6x1 6101 308 Brake Switch Brake Switch SCREW AND WASHER, M6x1.00x25.00, (NOT SERVICED) BRACKET, Brake Switch Mounting, (NOT SERVICED) 4671 336 SWITCH, Stop Lamp, Brake JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 113 RETAINER, (NOT SERVICED) NUT, U, M6x1 6101 308 SCREW AND WASHER, M6x1.00x25.00, (NOT SERVICED) BRACKET, Brake Switch Mounting, (NOT SERVICED) 4671 336 SWITCH, Stop Lamp JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 114 RETAINER, (NOT SERVICED) NUT, U, M6x1 6101 308 SCREW AND WASHER, M6x1.00x25.00, (NOT SERVICED) BRACKET, Brake Switch Mounting, (NOT SERVICED) 4671 336 SWITCH, Stop Lamp JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 115 GROUP 6 - Clutch Illustration Title Group-Fig. No. Clutch Clutch 1997 TJ 1998 TJ ............Fig.
  • Page 116 CLUTCH KIT, Manual Transmission 4874 175 CLUTCH PACKAGE 1150 0221 WASHER, Flat 3420 1373 BOLT, Hex Head, M8x1.25x22 6035 626 BOLT, Hex Head, .375-16x.84 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 117 CLUTCH KIT, Manual Transmission 4874 175 CLUTCH PACKAGE 1150 0221 WASHER, Flat 3420 1373 BOLT, Hex Head, M8x1.25x22 6035 626 BOLT, Hex Head, .375-16x.84 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 118 SPACER, Clutch Housing, Clutch Housing Six Cylinder 5209 8522 EP0, BRACKET, Tube, Vent Tube 1150 0986 BOLT, Hex Flange Head, M8x2.12x16, M8x2.12x16.00 5601 9959 CLIP, Wiring JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 119 53004 473AB SPACER, Clutch Housing 5209 8522 EP0, BRACKET, Tube BOLT, Hex Flange Head, M8x2.12x16 1150 0986 5601 9959 CLIP, Wiring JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 120 Reservoir Reservoir 5210 4013 COVER, Master Cylinder, Master Cylinder 0120 522 CLIP, Wrap Around, Wrap Around J400 3909 NUT, Hex Flange With Serration JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 121 CAP, Clutch Reservoir 4883 544AA 5210 4013 COVER, Master Cylinder CLIP, Wrap Around 0120 522 J400 3909 NUT, Hex Flange With Serration JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 122 4446 361 BUSHING, Hydraulic Clutch Actuator NUT, Hex Flange Lock, M6 Phosphate 6100 516 1997 TJ 1998 TJ PAD, Pedal 5200 2750 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 123 DDQ = Manual Transmission 5 Speed J400 3909 NUT, Hex Flange With Serration PEDAL, Brake 52128 017AB 52128 052AB PAD, Pedal 5200 2750 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 124 GROUP 7 - Cooling Illustration Title Group-Fig. No. Radiator and Related Parts Radiator And Related Parts 1997 TJ ..........Fig.
  • Page 125 6034 927 EP0, SCREW AND WASHER, Hex Head, .312-18x.970 HOSE, Radiator To Pump 5202 8141 5202 8143 5202 8265 SHROUD, Fan JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 126 0154 591 EP0, NUT AND WASHER, Hex, .312-18 FAN, Cooling 5200 4266 5202 7893 6034 860 EP0, BOLT AND WASHER, Implement Attaching JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 127 SCREW AND WASHER, Hex Head, .312-18x.970 HOSE, Radiator To Pump 5202 8141 5202 8143 5202 8265 SHROUD, Fan 5202 7925 5202 7926 5202 8127 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 128 5200 4266 0154 591 EP0, NUT AND WASHER, Hex, .312-18 5202 7893 FAN, Cooling 6034 860 EP0, BOLT AND WASHER, Implement Attaching JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 129 HOSE, Radiator To Pump 5202 8141 5202 8143 5202 8265 SHROUD, Fan 5202 7925 5202 7926 5202 8127 5202 8128 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 130 5202 7892 0154 591 EP0, NUT AND WASHER, Hex, .312-18 5202 7893 FAN, Cooling 6034 860 EP0, BOLT AND WASHER, Implement Attaching JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 131 EP0, SCREW AND WASHER, Hex Head, .312-18x1.12 J400 6714 EP0, STUD, .312-18/.312-24x1.250 5300 7978 EP0, TUBE, Water Pump Heater Return, Pump Heater Return JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 132 1998 TJ J400 4455 1999 TJ J400 6714 EP0, STUD, .312-18/.312-24x1.250 5300 7978 EP0, TUBE, Water Pump Heater Return, Pump Heater Return JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 133 BOTTLE, Coolant Recovery, Coolant HOSE, 5/8" I.D. 50 Foot Roll, (DNS), (NOT SERVICED) CLAMP, (NOT SERVICED) 5207 9331 EP0, CAP, Coolant Reserve Tank, Coolant Tank SCREW, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 134 BOTTLE, Coolant Recovery HOSE, 5/8" I.D. 50 Foot Roll, (DNS), (NOT SERVICED) CLAMP, (NOT SERVICED) 5207 9331 EP0, CAP, Coolant Reserve Tank SCREW, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 135 PULLEY, Power Steering Pump, Power Steering SCREW, (NOT SERVICED) 6503 198 EP0, BOLT, Adjusting Bracket SCREW, (NOT SERVICED) 5300 7154 EP0, PULLEY, Water Pump, Water Pump JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 136 1998 TJ # 53010 258AB EP0, 1999 TJ SCREW, (NOT SERVICED) 6503 198 EP0, BOLT, Adjusting Bracket SCREW, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 137 PART ITEM NUMBER LINE ENGINE TRANS DESCRIPTION 5300 7154 EP0, PULLEY, Water Pump JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd. Auto.
  • Page 138 53013 298AA EP0, Without A/C, With Power Steering, 1997 TJ LABEL, Belt Routing 5301 0298 EP0, Belt Routing 53013 005AA EP0, JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 139 With Air Conditioning 5301 0234 EP0, With Air Conditioning LABEL, Belt Routing 5301 0298 EP0, # 53013 005AB EP0, JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 140 5207 9688 4.0L 5207 9689 4.0L BRACKET, Transmission Oil Cooler 5211 8067 Cooler Lines to Oil Pan 5211 8116 LINE, Oil Cooler JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 141 1999 TJ 1999 TJ TUBE AND HOSE, Oil Cooler 5207 9687 5207 9688 5207 9689 5211 8067 BRACKET, Transmission Oil Cooler, Cooler Lines to Oil Pan JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 142 Radiator Guard, 1998 TJ, 1999 TJ ISOLATOR 5517 6181 Front End Sheet Metal, 1997 TJ Front End Sheet Metal, 1997 TJ 55176 181AB Front End Sheet Metal, 1998 TJ, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 143 June 7, 2002 »...
  • Page 144 GROUP 8 - Electrical GROUP 8 - Electrical Illustration Title Group-Fig. No. Illustration Title Group-Fig. No. Starters Lamps - Front, Rear and Courtesy Starter 1997 TJ 1999 TJ ............Fig.
  • Page 145 6035 607 SCREW, Starter Motor J324 1711 SHIM, Starter Motor NUT, (M5x0.80) Not Serviced ***, (NOT SERVICED) NUT, (M8x1.25) Not Serviced ***, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 146 6035 607 SCREW, Starter Motor J324 1711 SHIM, Starter Motor NUT, (M5x0.80) Not Serviced ***, (NOT SERVICED) NUT, (M8x1.25) Not Serviced ***, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 147 NUT, Plastic Inserted Self Locking, M4 x 0.70 6502 691 EPE, NUT, Hex Flange Lock, M6x1 BRACKET, Alternator And Compressor 5301 0207 Alternator & AC Mounting JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 148 ITEM NUMBER LINE SERIES BODY ENGINE TRANS DESCRIPTION Alternator & AC Mounting 5301 0273 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd. Auto.
  • Page 149 0.70 6502 691 EP0, NUT, Hex Flange Lock, M6x1 BRACKET, Alternator And Compressor 5301 0207 Alternator & AC Mounting Alternator & AC Mounting JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 150 0.70 6502 691 EP0, NUT, Hex Flange Lock, M6x1 BRACKET, Alternator And Compressor # 53010 224AB EP0, # 53013 281AB EP0, JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 151 GASKET, Distributor SHAFT, Distributor, Service w/Distributor, (NOT SERVICED) HOUSING, Distributor, Service w/ Distributor, (NOT SERVICED) SCREW, (NOT SERVICED) SPACER, Service w/Distributor, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 152 GASKET, Distributor SHAFT, Distributor, Service w/Distributor, (NOT SERVICED) HOUSING, Distributor, Service w/ Distributor, (NOT SERVICED) SCREW, (NOT SERVICED) SPACER, Distributor, Service w/ Distributor, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 153 GASKET, Distributor SHAFT, Distributor, Serviced w/ Distributor, (NOT SERVICED) HOUSING, Distributor, Serviced w/ Distributor, (NOT SERVICED) SCREW, (NOT SERVICED) SPACER, Distributor, Serviced w/ Distributor, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 154 SWITCHPLATE, Distributor 5602 7023 1997 TJ 5604 1030 1998 TJ WASHER, Distributor Gear 3300 4594 Thrust, 1997 TJ 1998 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 155 3300 4242 EP0, CLAMP, Distributor 6033 479 BOLT, Hex Head, .25-28x1-5/8 5604 1030 SWITCHPLATE, Distributor 3300 4594 WASHER, Distributor Gear JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 156 4671 346 MODULE, Security Alarm VELCRO PLATE, Trim Panel, (serviced In Assembly) , (NOT SERVICED) 56010 105AB MODULE, Air Bag Control SCREW, M6.3x1.81x20.00 , (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 157 56009 712AC MODULE, Security Alarm VELCRO PLATE, Trim Panel, (serviced In Assembly) , (NOT SERVICED) 56010 105AD MODULE, Air Bag Control SCREW, M6.3x1.81x20.00 , (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 158 56009 712AC MODULE, Security Alarm VELCRO PLATE, Trim Panel, (serviced In Assembly) , (NOT SERVICED) 56010 105AD MODULE, Air Bag Control SCREW, M6.3x1.81x20.00 , (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 159 Mandatory ( EXPORT), 1998 TJ, Mandatory (EXPORT) 1999 TJ RELAY PACKAGE, Electrical 4638 094 Electric Heated Rear Window 1998 TJ 1998 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...

  • Page 160: Figure

    5602 7727 Front 5602 7728 Right 5602 7729 Left 3420 2536 STUD, .312-18x2.26, Crank Sensor Mounting JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 161 5602 7727 Front 5602 7728 Rear (Right) 5602 7729 Rear (Left) 3420 2536 STUD, .312-18x2.26, Crank Sensor Mounting JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 162 Rear (Left) 6503 520 EP0, BOLT AND WASHER, Hex Head, M7x1. 00x25, Crank Sensor Attaching 3420 2536 STUD, .312-18x2.26, Crank Sensor Mounting JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 163 After July 24,1997 (FEDERAL/ CALIFORNIA) 56041 310AD After July 24,1997 (EUROPE w/Export Package) 56041 311AC After July 24,1997 (LEADED FUEL) Middle East JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 164 5010 405AB Before July 24,1997 (EUROPE w/ Export Package) SCREW, (.190-16x1.75) Not Serviced ***, (NOT SERVICED) 5603 8455 EP0, COVER, Module, Motorola JTEC Module JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 165 56041 629AE w/Automatic Transmission (LEADED FUEL) SCREW, (.190-16x1.75) Not Serviced ***, (NOT SERVICED) 5603 8455 EP0, COVER, Module, Motorola JTEC Module JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 166 CALIFORNIA # 56041 471AC EUROPE # 56041 472AC LEADED FUEL SCREW, (.190-16x1.75) Not Serviced ***, (NOT SERVICED) COVER, Module, (NOT REQUIRED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 167 SWITCH, Intermittent Wiper 4793 313 5600 9135 SWITCH, Multifunction SWITCH, Back Up Lamp 8350 0629 Back-Up Lamp, Man. Trans. Back-Up Lamp, Man. Trans. JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 168 A/C Low Pressure Cycling 4687 558 SWITCH, Door Ajar J093 4001 ELBOW, Oil Gauge Sending Unit 5600 6315 SWITCH, Anti Lock Brake Accelarat, G Switch JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 169 8350 0629 4565 326 SWITCH, Ignition SWITCH, Headlamp 56009 869AA 5600 9047 SWITCH, Clutch Starter Interlock, Clutch Starter Interlock SWITCH, Power Steering JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...

  • Page 170: Figure

    ELBOW, Oil Gauge Sending Unit 5600 6315 SWITCH, Anti Lock Brake Accelarat, G Switch SWITCH, Speed Control 56007 530AC Right 56007 531AC Left JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 171 4793 313 SWITCH, Multifunction 5600 9135 4863 839 CONNECTOR PACKAGE, Beam Select Switch SWITCH, Back Up Lamp 8350 0629 SWITCH, Ignition JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 172 # 56006 315AB SWITCH, Anti Lock Brake Accelarat, G Switch SWITCH, Speed Control # 56007 530AD Right # 56007 531AD Left JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 173 56009 768AB HORN, High Note 6502 767 SCREW, Tap, M8x1.25x22 BRACKET, Horn Mounting (Serviced In Assembly Item # 1), (NOT SERVICED) 5600 9769 HORN, Duel JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 174 56009 769AB HORN, Duel 56009 768AC HORN, High Note, (EUROPE) SCREW, Tap, M8x1.25x22, (NOT SERVICED) BRACKET, Horn Mounting (Serviced In Assembly Item # 1), (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 175 5601 8745 EP0, R.H.D. 56010 208AA L.H.D. PROTECTOR, Wiring 5517 6426 4641 780 STRAP, Tie JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 176 WIRING, Battery 56041 445AA 56041 446AA 56041 447AA 56041 448AA 55176 426AB PROTECTOR, Wiring 4641 780 STRAP, Tie JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 177 WIRING, Battery # 56041 445AB # 56041 446AB # 56041 447AB # 56041 448AB 55176 426AB PROTECTOR, Wiring 4641 780 STRAP, Tie JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 178 LAMP, Side Marker 55155 628AB Use Socket & Wiring Assembly 04450824 (Repair), Right 55155 629AB Use Socket & Wiring Assembly 04450824 (Repair), Left LAMP, Side Repeater JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 179 BRACKET, License Plate, EUROPE 6030 441 EP0, PIN, Retainer SCREW, M6X1.00X16.00, (NOT SERVICED) NUT, M6x1.00, (NOT SERVICED) 5601 7442 WIRING, Courtesy Lamp JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 180 ITEM NUMBER LINE SERIES BODY ENGINE TRANS DESCRIPTION L0HJ 6024 HEADLAMP JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd. Auto.
  • Page 181 55055 095AB LAMP, Fog, Fog (Black 6100 052 NUT AND WASHER, Hex, M8x1.25 4864 773 RETAINER, Fog Lamp Bulb 5602 1441 LAMP, Underhood JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 182 EP0, PIN, Retainer SCREW, M6X1.00X16.00, (NOT SERVICED) NUT, M6x1.00, (NOT SERVICED) 5601 7442 WIRING, Courtesy Lamp L0HJ 6024 HEADLAMP JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 183 Leveling System (AUSTRALIA, SOUTH AFRICA, SOUTH KOREA, UNITED KINGDOM, UNITED KINGDOM MARKET PACKAGE) 4874 382 ACTUATOR, Headlamp 55155 764AB BRACKET, License Plate, Export JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 184 NUT, M6x1.00, (NOT SERVICED) # 56042 559AA LAMP, Courtesy, I/Panel Harness 4863 839 CONNECTOR PACKAGE, Beam Select Switch L0HJ 6024 HEADLAMP, Seal Beam (H6024) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 185 0154 631 SCREW, Pan Head, .190-16x.5 SCREW, M6x1x20, (NOT SERVICED) NUT, M6x1.00, (NOT SERVICED) SCREW, M6X1.00X16.00, (NOT SERVICED) 4687 558 SWITCH, Door Ajar JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 186 0154 631 SCREW, Pan Head, .190-16x.5 SCREW, M6x1x20, (NOT SERVICED) NUT, M6x1.00, (NOT SERVICED) SCREW, M6X1.00X16.00, (NOT SERVICED) 4687 558 SWITCH, Door Ajar JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 187 0154 631 SCREW, Pan Head, .190-16x.5 SCREW, M6x1x20, (NOT SERVICED) NUT, M6x1.00, (NOT SERVICED) SCREW, M6X1.00X16.00, (NOT SERVICED) 4687 558 SWITCH, Door Ajar JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 188 Sound Bar SCREW, (NOT SERVICED) J095 9978 LENS, Dome Lamp, Liftgate Courtesy Lamp J095 9999 HOUSING, Dome and Reading Lamp, Liftgate Courtesy Lamp JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 189 Lamp SCREW, (NOT SERVICED) J095 9978 LENS, Dome Lamp, Liftgate Courtesy Lamp, Rear J095 9999 HOUSING, Dome and Reading Lamp, Liftgate Courtesy Lamp JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 190 Lamp SCREW, (NOT SERVICED) J095 9978 LENS, Dome Lamp, Liftgate Courtesy Lamp J095 9999 HOUSING, Dome and Reading Lamp, Liftgate Courtesy Lamp JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 191 BULB, 37 L000 0658 BULB, 658, Miniature (T-3 1/4 Wedge) 4874 122AB BULB AND SOCKET, Graphic Illumination 4874 123 BULB AND SOCKET, Switch on Indicator JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 192 BULB, 37 L000 0658 BULB, 658 4874 122 BULB AND SOCKET, Graphic Illumination 4874 122AB BULB AND SOCKET, Switch On Indicator JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 193 Illumination BULB AND SOCKET 4874 122AB Switch On Indicator 4874 123 Switch on Indicator # 5013 829AA BULB, Heater and A/C Control JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 194 5601 0212 Automatic Transmission, 1997 TJ 56010 212AB w/Automatic Transmission, 1998 TJ, 1999 TJ 5600 9433 CAP, Screw Cover PLUG, Oxygen Sensor JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 195 MIDDLE EAST PKGE.) *** 1997, Mandatory ( MIDDLE EAST PACKAGE), 1998 TJ, Mandatory (MIDDLE EAST PACKAGE) EP0, 02 Sensor Plug (MIDDLE EAST, MIDDLE EAST PKGE.) *** 1997, 1999 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 196 56009 719AB w/Dual Road Foglamp 56009 720AB w/o Dual Road Foglamp 5600 9755 EUROPE 56009 901AA BRACKET, Wiring Harness, Battery & Engine JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 197 WIRING, Park Lamp Jumper, (NOT REQUIRED) BRACKET, Wiring Harness 56009 901AA Battery & Engine 5601 9684 Side Cowl 5601 9685 Side Cowl JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 198 WIRING, Park Lamp Jumper, (NOT REQUIRED) 56009 901AA BRACKET, Wiring Harness, Battery & Engine 4863 839 CONNECTOR PACKAGE, Beam Select Switch JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 199 00MA X40 1998 TJ, 1999 TJ 6101 641 1997 TJ FLASHER 5600 9339 USA/CANADA 5600 9345 EUROPE JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 200 BRACKET, Wiring Harness 56009 901AA Battery & Engine, 1998 TJ 5601 9684 1997 TJ Side Cowl, 1998 TJ 5601 9685 1997 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 201 Top to Top (Jumper) ***, 1997 TJ 1998 TJ 56009 333AB CLIP, Wiring Attaching RIVET (NOT REQUIRED), 1997 TJ 56009 338AB 1998 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 202 56009 896AA WIRING, Soundbar Adapter, Soundbar (Jumper) EUROPE *** 56009 939AA WIRING, Jumper 56009 333AB CLIP, Wire Attaching (Clip) 56009 338AB RIVET JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 203 ENGINE TRANS DESCRIPTION 5013 930AA WIRING PACKAGE, Underhood Connector Repair 4863 839 CONNECTOR PACKAGE, Beam Select Switch JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 204 ENGINE TRANS DESCRIPTION 5013 930AA WIRING PACKAGE, Underhood Connector Repair 4863 839 CONNECTOR PACKAGE, Beam Select Switch JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 205 ENGINE TRANS DESCRIPTION 5013 930AA WIRING PACKAGE, Underhood Connector Repair 4863 839 CONNECTOR PACKAGE, Beam Select Switch JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 206 ITEM NUMBER LINE SERIES BODY ENGINE TRANS DESCRIPTION 5014 460AA REPAIR KIT, Power Distribution Center JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 207 3300 7154 5300 6579 COIL, Ignition 4797 293 BRACKET, Ignition Coil 5300 8702 Coil Mounting 5602 6890 Coil Mounting JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 208 RC-12-LYC, 2.5L & 4.0L Engine SEPERATOR, Ignition Cable 3300 7154 5300 6579 COIL, Ignition 5602 8172 BRACKET, Ignition Coil 5300 8702 5602 6890 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 209 # 56041 402AB SEPERATOR, Ignition Cable 3300 7154 5300 6579 COIL, Ignition 5602 8172 BRACKET, Ignition Coil 5300 8702 5602 6890 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 210 GROUP 8A - Instrument Panel and Radios and Consoles Illustration Title Group-Fig. No. Instrument Panel Instrument Panel 1997 TJ ............Fig.
  • Page 211 5EE1 1TT6 Saddle Saddle 5511 5170 STRIKER, Glove Box Door Latch, I/Panel Glove Box 5600 7282 AIR BAG, Passenger, Passenger Air Bag DOOR, Passenger Air Bag JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 212 56007 314AB BEZEL, Cigar Lighter, Bezel & Plug, 3 Switch Openings & Cigar Lighter 5600 7330 PLUG, Switch Opening 4372 399 COVER, Radio Opening, I/Panel Radio Opening JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 213 Gray 5EE1 1TT6 Saddle Saddle 5511 5170 STRIKER, Glove Box Door Latch AIR BAG, Passenger 55314 982AA DOOR, Passenger Air Bag JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 214 5600 7330 PLUG, Switch Opening 4372 399 COVER, Radio Opening, I/Panel Radio Opening 5FK5 7TAZ BEZEL, Instrument Panel, Center, Black Ash Tray Clips Included (Agate) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 215 HANDLE, Grab, Bezel Only 5EE1 1LAZ Agate Agate 5EE1 1RK5 Tan/Agate Tan/Agate STRIKER, Glove Box Door Latch 5511 5170 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 216 5600 7330 PLUG, Switch Opening 4372 399 COVER, Radio Opening, I/Panel Radio Opening 6503 698 SCREW AND WASHER, Truss Head, M6-1.00x30.00, I/ Panel to Cowl Attaching JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 217 4874 122 1998 TJ 4874 349 1997 TJ 1997 TJ BULB, PC74 L000 PC74 1997 TJ 1998 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 218 LENS, Cluster 4874 346 GROMMET, Speedometer Trip Reset 4874 348 COVER, Cluster 4874 349 BULB AND SOCKET L000 PC74 BULB, PC74 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 219 RADIO, AM/FM with CD, RBA 5269 484 RADIO, RBL (4 Speakers w/Sound Bar) STRAP, Ground 5600 9161 Engine to Frame to Hood 5600 9160 Engine to Frame JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 220 RAL ( w/2 Speakers) 4858 560AD RAL ( w/4 Speakers) STRAP, Ground 5600 9161 Engine to Frame to Hood 5600 9160 Engine to Frame JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 221 4858 560AD (RAL) w/ 4 Speakers w/Sound Bar 5600 9159 STRAP, Ground, Radio Rear 5600 9160 STRAP, Ground, Engine/Frame 5600 9161 STRAP, Ground, Engine/Body/Hood JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 222 5603 8504 COVER, Antenna Opening 5600 8929 PLUG, Antenna Hole GROMMET, Antenna, (NOT SERVICED) 5600 8786 CABLE, Antenna SCREW, .164-18x.75, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 223 5603 8504 COVER, Antenna Opening 5600 8929 PLUG, Antenna Hole GROMMET, Antenna, (NOT SERVICED) 5600 8786 CABLE, Antenna SCREW, .164-18x.75, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 224 5603 8504 COVER, Antenna Opening 5600 8929 PLUG, Antenna Hole GROMMET, Antenna, (NOT SERVICED) 5600 8786 CABLE, Antenna SCREW, .164-18x.75, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 225 SPEAKER, Sound Bar 4874 295 4874 296 GRILLE, Speaker, Sound Bar (5.25) 5600 7264 BEZEL, Dome Lamp 5600 7265 LENS, Dome Lamp JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 226 SPEAKER, 5.25" 4874 296 GRILLE, Speaker 5600 7264 BEZEL, Dome Lamp 5600 7265 LENS, Dome Lamp L000 0912 BULB, 912 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 227 SPEAKER, 5.25" # 4874 296AB GRILLE, Speaker 5600 7264 BEZEL, Dome Lamp 5600 7265 LENS, Dome Lamp L000 0912 BULB, 912 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 228 STRIKER, Console Lid Catch, (Serviced in CONSOLE), (NOT SERVICED) 55037 380AA SEAL, Lid, Console Lid 4507 482 HOLDER, Coin, Coin Rear Console 4741 954 LATCH, Storage Bin Lid JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 229 55315 000AA PLUG, Cover 4507 482 HOLDER, Coin 4741 954 LATCH, Storage Bin Lid 5012 482AA COVER, Switch Opening, without Airbag Shutoff Switch JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 230 5GL51 DX9AB 1 BEZEL, Floor Console, Passenger Airbag Disarm Switch (Black) 56010 056AA SWITCH, Passenger Airbag Disarm 55315 000AB PLUG, Cover, w/Tether HOLDER, Coin, (NOT REQUIRED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 231 GROUP 9 - Engine Mounting Illustration Title Group-Fig. No. Engine Mounting Engine Mounting, Front 2.5L (EPE) Engine ......... . . Fig.
  • Page 232 (NOT REQUIRED), 1998 TJ, 1999 TJ 6502 135 1997 TJ NUT, Hex Flange Lock, M10x1.5 (NOT REQUIRED), 1997 TJ 6502 696 1998 TJ, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 233 6502 337 NUT, M10x1.5 6100 517 NUT, Hex Flange Lock, M8 Phosphate BOLT, M8x1.25x25.00, (NOT SERVICED) WASHER, (NOT SERVICED) 5205 8863 BRACKET, Transmission Mount JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 234 (NOT REQUIRED), 1998 TJ, 1999 TJ 6502 135 1997 TJ NUT, Hex Flange Lock, M10x1.5 (NOT REQUIRED), 1997 TJ 6502 696 1998 TJ, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 235 6502 337 NUT, M10x1.5 6100 517 NUT, Hex Flange Lock, M8 Phosphate BOLT, M8x1.25x25.00, (NOT SERVICED) WASHER, (NOT SERVICED) 5205 8863 BRACKET, Transmission Mount JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 236 GROUP 2.5L4 - Engine 2.5L Four Cylinder Illustration Title Group-Fig. No. Cylinder Head Cylinder Head 2.5L (EPE) Engine ..........Fig.
  • Page 237 1998 TJ, 1999 TJ BOLT, Hex Flange Pilot Point, .250-20x1.97 (NOT REQUIRED), 1998 TJ, 1999 TJ 6034 477 1997 TJ STUD, Double Ended, .25-20x1.97 (NOT REQUIRED), 1998 TJ, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 238 1997 TJ STUD, .250-20x2.00 (NOT REQUIRED), 1997 TJ 6035 968AA 1998 TJ, 1999 TJ 5302 0555 CAP, Oil Filler GASKET, Cylinder Cover, RTV Sealant, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 239 CORD, Engine Block Heater 5602 6888 HEATER, Engine Block GASKET PACKAGE, Engine 4713 023 1997 TJ 1997 TJ 4713 023AC 1998 TJ, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 240 BEARING KIT, Connecting Rod, .001 Undersize 8350 0301 EP0, BEARING KIT, Connecting Rod, .010 Undersize PISTON PIN AND ROD 4798 329 B Size, 3.8746, 1997 TJ, 1998 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 241 4736 388 1997 TJ 4736 388AB 1998 TJ, 1999 TJ 6034 780 BOLT, Hex Head, .437-24x1.20 5210 4139 PLATE, Torque Converter Drive JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 242 1999 TJ SPRING, Valve 5301 0388 1998 TJ 1999 TJ 5302 0556 1997 TJ J324 1709 PUSH ROD, FRONT SUSPENSION JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 243 TAPPET, Valve J045 6384 DOWEL, Camshaft Sprocket J323 6513 BRIDGE, Rocker Arm J324 2393 ROCKER ARM, Valve J323 5090 PIVOT, Rocker Arm JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 244 1999 TJ SCREW (NOT REQUIRED), 1997 TJ, 1998 TJ # 6035 895 EP0, 1999 TJ 5302 0222 EP0, COVER, Timing Belt JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 245 PART ITEM NUMBER LINE ENGINE TRANS DESCRIPTION 3300 4681 EP0, SEAL, Front Main Crankshaft JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd. Auto.
  • Page 246 1997 TJ EP0, 1998 TJ, 1999 TJ 5301 0343 TUBE, Oil Filler 6035 417 PLUG, Oil Drain GASKET, Oil Drain Plug, Serviced in Plug, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 247 NUMBER LINE ENGINE TRANS DESCRIPTION 5300 7567 GASKET, Oil Pan J324 3116 SUPPORT, Engine Oil Pan JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 248 EP0, 1999 TJ 5301 0165 EP0, 1997 TJ, 1998 TJ 3300 3332 SPACER, Exhaust Manifold 4854 194 FITTING, Vacuum JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 249 TUBE, Crankcase Vent Valve 5303 0497 EP0, FITTING, Crankcase Vent Tube 3300 4175 CONNECTOR, Vacuum Hose 2946 079 GROMMET, Crankcase Vent JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 250 GROUP 4.0L - Engine 4.0L Six Cylinder Illustration Title Group-Fig. No. Cylinder Head Cylinder Head 4.0L (ERH) Engine ..........Fig.
  • Page 251 4777 536 CAP, Oil Filler GASKET, Valve Cover 53020 758AB 1997 TJ 53020 758AC 1998 TJ, 1999 TJ SLEEVE, Torque Limiter JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 252 1998 TJ, 1999 TJ 5301 0424 GROMMET, Insulator PLUG, Pipe, .125-27x3.50 (NOT REQUIRED), 1998 TJ, 1999 TJ 6035 687 EP0, 1997 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 253 1997 TJ 1997 TJ 4740 008AC 1998 TJ, 1999 TJ 0141 215 DOWEL, .312 x .500 5302 0465 PLUG, Cylinder Block JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 254 8350 7090 EP0, BEARING PACKAGE, Crankshaft Thrust, .010" Undersize 8350 0300 BEARING KIT, Connecting Rod, Standard 8350 1397 EP0, BEARING KIT, Connecting Rod, .001 Undersize JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 255 F Size, 3.8758, 1999 TJ PIN, Piston, Serviced in Piston Assembly, (NOT SERVICED) RING PACKAGE, Piston, Standard Size Complete Engine 4798 878 ROD, Connecting, Serviced in Piston Assembly, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 256 1997 TJ, 1998 TJ 53010 515AA 1999 TJ SPRING, Valve 5301 0388 1998 TJ, 1999 TJ 5302 0556 1997 TJ RETAINER, Valve Spring JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 257 J324 2393 ROCKER ARM, Valve J323 5090 PIVOT, Rocker Arm J323 6513 BRIDGE, Rocker Arm J942 5708 BOLT, Hex Flange Head, .312-18x1.25 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 258 BOLT, Hex Head Shoulder, .312-18x1.56 SCREW, (NOT REQUIRED) 8350 2890 PIN PACKAGE, Camshaft Thrust 3300 3446 EP0, SNUBBER, Timing Chain PLATE, Camshaft Thrust, (NOT REQUIRED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 259 BOLT, Hex Head Shoulder, .312-18x1.56 SCREW, (NOT REQUIRED) 8350 2890 PIN PACKAGE, Camshaft Thrust 3300 3446 EP0, SNUBBER, Timing Chain PLATE, Camshaft Thrust, (NOT REQUIRED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...

  • Page 260: Figure

    PIN PACKAGE, Camshaft Thrust, (NOT REQUIRED) 3300 3446 EP0, SNUBBER, Timing Chain # 5301 0401 PLATE, Camshaft Thrust # 6035 975AA SCREW, Pan Head JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 261 SCREW, Hex Head Coned, .312-18x.875 6034 733 STUD, .312-18/.250-20x1.680 5300 7568 GASKET, Oil Pan 6034 734 BOLT, Double Stud Hex, .250-20x1.437 & .250-20 x.700 STUD, .312-18x1.560 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 262 ITEM NUMBER LINE ENGINE TRANS DESCRIPTION 6035 664 1997 TJ EP0, 1998 TJ, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 263 FITTING, Vacuum, 90 Degree (NOT REQUIRED), 1999 TJ 5303 0756 1997 TJ, 1998 TJ PLUG, Pipe (NOT REQUIRED), 1998 TJ, 1999 TJ 0444 654 1997 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 264 TUBE, Crankcase Vent To Air Cleaner 5303 0497 EP0, FITTING, Crankcase Vent Tube 4854 194 FITTING, Vacuum 2946 079 GROMMET, Crankcase Vent JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 265 GROUP 11 - Exhaust Illustration Title Group-Fig. No. Exhaust System Exhaust System 2.5L (EPE), 4.0L (ERH) Engine ........Fig.
  • Page 266 CONVERTER, Catalytic (NOT REQUIRED), 1997 TJ, 1998 TJ # 52018 933AC DBB, Federal, Europe, 1999 TJ # 52101 129AA DBB, California, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 267 1999 TJ 5201 9408 HANGER, Muffler 5210 1035 INSULATOR, Exhaust J400 1933 SCREW, Hex Flange Head, .312-x18x. 5201 9413 HANGER, Exhaust JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 268 1997 TJ 1998 TJ, 1999 TJ SCREW, .250-20x.625, (NOT SERVICED) NUT, Hex, .250-20 J012 0375 1997 TJ, 1998 TJ 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 269 GROUP 13 - Frames and Bumpers Illustration Title Group-Fig. No. Frames Frame 1997 TJ ............. . . Fig.

  • Page 270: Frame Rail

    Upper, w/2.5L Eng., Right Upper, w/2.5L Eng., Right 5205 8871 Upper, w/2.5L Eng., Left Upper, w/2.5L Eng., Left REINFORCEMENT, Engine Mount 5205 8846 Right JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...

  • Page 271: Frame Rail

    Rear Crossmember, Right Rear Crossmember, Right 5205 8773 Rear Suspension, Left Rear Suspension, Left BRACKET, Frame Rail 5205 8420 Spring Mtg., Right JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 272 BRACKET, Upper Control Arm 5205 8466 Right Right 5205 8467 Left Left 5205 8551 MOUNT, Transmission, Trans. Support JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.

  • Page 273: Frame Rail

    Upper, w/2.5L Eng., Left REINFORCEMENT, Engine Mount 5205 8846 Right Right 5205 8847 Left Left REINFORCEMENT, Engine Mount JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.

  • Page 274: Frame Rail

    BRACKET, Frame Rail 5205 8420 Spring Mtg., Right Spring Mtg., Right 5205 8421 Spring Mtg., Left Spring Mtg., Left BRACKET, Stabilizer Bar JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 275 BRACKET, Upper Control Arm 52058 466AB Right Right 52058 467AB Left Left 52058 551AB MOUNT, Transmission, Trans. Support JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.

  • Page 276: Frame Rail

    Upper, w/2.5L Eng., Right Upper, w/2.5L Eng., Right 5205 8871 Upper, w/2.5L Eng., Left Upper, w/2.5L Eng., Left REINFORCEMENT, Engine Mount 5205 8846 Right JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...

  • Page 277: Frame Rail

    5205 8773 Left Left BRACKET, Frame Rail 5205 8420 Spring Mtg., Right Spring Mtg., Right 5205 8421 Spring Mtg., Left JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 278 Right Right 52058 467AB Left Left 52058 551AB MOUNT, Transmission, Trans. Support SKID PLATE, Support # 52058 133AC JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 279 SCREW, (NOT SERVICED) 6504 662 RETAINER, Push On, Plate Screw NUT, (NOT SERVICED) COVER, Bumper 5515 5668 Right 5515 5669 Left JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 280 NUT, (NOT SERVICED) COVER, Bumper 55155 667AC 1998 TJ # 55155 667AF 1999 TJ GUARD, Bumper 52000 240AB 1998 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 281 Figure 013-210 PART ITEM NUMBER LINE SERIES BODY DESCRIPTION # 52000 240AC 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd. Auto.
  • Page 282 SCREW, (NOT SERVICED) 3420 1686 BOLT, Hex Flange Head, M12x1.18x35 HOOK, Tow 5200 1644 1997 TJ, 1998 TJ # 52059 379AA 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 283 INSULATOR, Body Hold Down 5517 6180 Lower Body Mount, 1997 TJ Lower Body Mount, 1997 TJ 1998 TJ, 1999 TJ J400 7571 SCREW, Hex Flange Head, .50-13x3.75 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 284 June 7, 2002 »...
  • Page 285 GROUP 14 - Fuel Illustration Title Group-Fig. No. Tank, Fuel Fuel Tank 2.5L (EPE), 4.0L (ERH) Engine ......... . . Fig.
  • Page 286 CAP, Support Strap Stud J400 3954 NUT, Hex J400 5293 RETAINER, Push In Type M6.3 Hole 5210 0219 PLATE, Skid J400 3587 NUT, Hex JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 287 CLAMP, Hose 5210 0033 EP0, HOSE, Fuel Tank Vent 0153 832 SCREW, .190-16x1.00 5210 0212 EP0, STRAP, Ground JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 288 CLAMP, Hose 5210 0033 EP0, HOSE, Fuel Tank Vent 0153 832 SCREW, .190-16x1.00 5210 0212 EP0, STRAP, Ground JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 289 CLAMP, Hose 52100 033AD EP0, HOSE, Fuel Tank Vent 0153 832 SCREW, .190-16x1.00 5210 0212 EP0, STRAP, Ground JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 290 CLIP, Fuel Line (NOT SERVICED), 1999 TJ 6504 589 1997 TJ, 1998 TJ 6101 786 SCREW, Self Tapping, M6x1x15 5212 7788 CLIP, Fuel Line JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 291 BUNDLE, Fuel Line HFV0 0316 EP0, HOSE, Fuel And Vapor, 25 Foot Roll 3/ 16" 52100 185AB EP0, HOSE, Fuel Vapor JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 292 6100 047 NUT AND WASHER, Hex Nut-Coned Washer, M6 x 1.00 SCREW, Hex Head Tapping, M6.3x1. 81x16.00 3420 1895 1997 TJ 1998 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 293 Note; ER0= All 4.0L Engines # 52100 272AF BUNDLE, Fuel Line 5212 7788 CLIP, Fuel Line # 6505 600AA STUD BRACKET, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 294 BUNDLE, Fuel Line HFV0 0316 EP0, HOSE, Fuel And Vapor, 25 Foot Roll 3/ 16" 52100 185AB EP0, HOSE, Fuel Vapor JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 295 STUD STUD, M6x1.00x44 6502 647 1997 TJ, 1998 TJ 1999 TJ 5018 781AA Diagnostic Port Diagnostic Port, 1998 TJ, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 296 4897 757AC EP0, 19 Gallon, 1998 TJ, 1999 TJ 4798 301 EP0, FILTER, Fuel FILTER, Fuel Module, Serviced in Module Assembly, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 297 1999 TJ 1999 TJ 5303 0820 1998 TJ 5303 0821 1998 TJ 5300 7543 EP0, GASKET, Throttle Body JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 298 EP0, SPRING, Throttle Return 5207 8987 GUIDE, Accelerator Cable NUT AND WASHER, Hex Nut-Coned Washer, M6 x 1.00 6100 047 1997 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 299 5303 0611 5303 0759 RESONATOR, Air Cleaner 6504 503 SCREW, Hex Flange Head TUBE, Crankcase Vent Valve 5303 0614 5303 0615 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 300 6025 867 NUT, Hex Flange Serration, M6x1 6502 493 SERVO, Speed Control 4669 979 HARNESS, Speed Control Vacuum 53013 010AA 53013 063AA JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 301 NUT, Hex Flange, M6x1 SPRING, Torsion 5303 0874 EP0, EP0, PIN, Accelerator Pedal Mtg. 5207 9019 EP0, EP0, JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 302 GROUP 16 - Propeller Shafts and U-Joints Illustration Title Group-Fig. No. Propeller Shaft Propeller Shaft and Universal Joint Wrangler (TJ) 1997 TJ ....... Fig.
  • Page 303 DRJ (U-Joint Serviced in Assy,) 5209 8785 5209 8787 FITTING PACKAGE, Grease 8350 7064 Grease Grease 6034 966 BOLT, .312-24x1.170 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 304 5209 8785 w/4.0L w/Auto Trans (DRK) 5209 8787 EN0, w/4.0L w/Man (DRK) 8350 7064 FITTING PACKAGE, Grease 6034 966 BOLT, .312-24x1.170 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...

  • Page 305: J812

    Front BOOT, Driveshaft 5012 793AA Front Front Front YOKE, Drive Shaft 5010 030AA Front Front JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 306 ENGINE TRANS DESCRIPTION Front RING, U Joint J320 7886 Front and Rear Front and Rear Front and Rear JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 307 GROUP 17 - Rear Suspension Illustration Title Group-Fig. No. Rear Suspension Suspension, Rear w/Shock Absorber 1997 TJ ......... Fig.
  • Page 308 LINK, Sway Eliminator, Stabilizer Rear 6503 726 SCREW, Shoulder, M10x1.50x66.00 6502 696 NUT, Hex Flange Lock, M10x1.5, M10x1. 5208 7865 RETAINER, Sway Bar, Stabilizer Bar Bushing JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 309 6503 982 M12x1.75x80.00 M12x1.75x80.00 3420 2467 SCREW, Hex Head, M8x1.25x30, M8x1. 25x30.00 NUT AND RETAINER, Hex Flange Lock, m8x1.25 6503 648 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 310 NUT AND RETAINER, Hex Flange Lock, m8x1.25 SPRING, Rear Coil 5208 9102 (ZAT,ZNT) 5208 9103 (ZAU,ZNU) 5208 9104 (ZAV,ZNV) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 311 6503 982 SCREW, Hex Flange Head, M12x1.75x80 3420 2467 SCREW, Hex Head, M8x1.25x30 6503 648 NUT AND RETAINER, Hex Flange Lock, m8x1.25 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 312 NUT AND RETAINER, Hex Flange Lock, m8x1.25 SPRING, Rear Coil 5208 9102 (ZAT,ZNT) 5208 9103 (ZAU,ZNU) 5208 9104 (ZAV,ZNV) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 313 6503 982 SCREW, Hex Flange Head, M12x1.75x80 3420 2467 SCREW, Hex Head, M8x1.25x30 6503 648 NUT AND RETAINER, Hex Flange Lock, m8x1.25 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 314 NUT, Hex Flange Lock, M10x1.5, M10x1. 5208 7865 RETAINER, Sway Bar, Rear 5208 8125 BUSHING, Sway Bar, Stabilizer Bar 14.5 Dia. 6502 985 SCREW AND WASHER, M10x1.50x35 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 315 NUT, Hex Flange Lock, M10x1.5 5208 7865 RETAINER, Sway Bar, Rear 5208 8125 BUSHING, Sway Bar, Stabilizer Bar 14.5 Dia. 6503 571 SCREW AND WASHER, M10x1.50x35 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 316 NUT, Hex Flange Lock, M10x1.5, M10x1. 5208 7865 RETAINER, Sway Bar, Rear 5208 8125 BUSHING, Sway Bar, Stabilizer Bar 14.5 Dia. 6503 571 SCREW AND WASHER, M10x1.50x35 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 317 GROUP 19 - Steering Illustration Title Group-Fig. No. Steering Wheel Wheel, Steering 1997 TJ ............Fig.
  • Page 318 COVER, Air Bag Module, Includes Horn Switch 6503 262 SCREW, Hex Flange Head, M6x1.00x20.00 6500 906 NUT, Hex Flange Lock, M14x1.5, Steering Wheel Attaching 56009 070AB CLOCKSPRING JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 319 SCREW, Hex Flange Head, M6x1.00x20.00 6505 248AA NUT, Hex Flange Lock, Steering Wheel Attaching CLOCKSPRING 56009 070AB w/o Speed Control 56009 071AB w/Speed Control JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 320 SCREW, Hex Flange Head, M6x1.00x20.00 6505 248AA NUT, Hex Flange Lock, Steering Wheel Attaching CLOCKSPRING 56009 070AB w/o Speed Control 56009 071AB w/Speed Control JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 321 5205 8841 5205 8854 5205 8855 52058 856AB SCREW AND WASHER, Hex Head, M10x1.5x35 6504 153 M10x1.50x35.00 M10x1.50x35.00 SHAFT, Intermediate JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 322 SERIES ENGINE TRANS DESCRIPTION 5207 8705 Power Steering 5207 8804 6100 516 NUT, Hex Flange Lock, M6 Phosphate, M6X1.00 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 323 5205 8841 5205 8854 5205 8855 52058 856AB 6504 153 SCREW AND WASHER, Hex Head, M10x1.5x35 SHAFT, Intermediate 5207 8705 Power Steering JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 324 NUMBER LINE SERIES ENGINE TRANS DESCRIPTION 5207 8804 6100 516 NUT, Hex Flange Lock, M6 Phosphate, M6X1.00 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 325 6504 153 SCREW AND WASHER, Hex Head, M10x1.5x35 SHAFT, Intermediate 5207 8705 Power Steering 5207 8804 6100 516 NUT, Hex Flange Lock, M6 Phosphate JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 326 TRANS DESCRIPTION 5200 0089 GEAR, Manual Steering SCREW AND WASHER, Hex Head 6035 006 NUT AND WASHER, Hex, .437-14x1.380, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 327 TRANS DESCRIPTION 5200 0089 GEAR, Manual Steering 6035 006 SCREW AND WASHER, Hex Head NUT AND WASHER, Hex, .437-14x1.380, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 328 SEAL, Steering Gear Cover 3893 558 SEAL KIT, Steering gear adjuster plug 4886 349AA SEAL KIT, Steering gear end plug 3893 557 6101 467 NUT, Hex Flange, M8x1.25 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 329 SEAL, Steering Gear Cover 3893 558 4886 349AA SEAL KIT, Steering gear adjuster plug SEAL KIT, Steering gear end plug 3893 557 6101 467 NUT, Hex Flange, M8x1.25 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 330 3893 558 4886 349AA SEAL KIT, Steering gear adjuster plug SEAL KIT, Steering gear end plug 3893 557 6101 467 EP0, NUT, Hex Flange, M8x1.25 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 331 ARM, Pitman 5203 8337 Power Steering 5203 8338 5208 7883 NUT, Steering Gear Arm, (NOT SERVICED) 5208 7674 TUBE, Tie Rod JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 332 Steering 5203 8338 w/RHD 5208 7883 w/LHD w/Man, Steering NUT, Steering Gear Arm, (NOT SERVICED) 5208 7674 TUBE, Tie Rod JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 333 SERVICED) ARM, Pitman 5203 8337 w/LHD 5203 8338 w/RHD NUT, Steering Gear Arm, (NOT SERVICED) 5208 7674 TUBE, Tie Rod JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 334 ER0 = All 4.0L 6 Cyl Gas Engines J=Dana 35 Rear Axle---DRK=Dana 44 Rear Axle 5208 8018 PUMP, Power Steering 5208 7871 PUMP, Power Steering 4897 287AA CAP, Power Steering Reservoir JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 335 EP0 = All 2.5L 4 Cyl Gas Engines J=Dana 35 Rear Axle---DRK=Dana 44 Rear Axle ER0 = All 4.0L 6 Cyl Gas Engines J=Dana 35 Rear Axle---DRK=Dana 44 Rear Axle PUMP, Power Steering 52087 871AD 5208 8018 4694 766 CAP, Power Steering Pump JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 336 ER0 = All 4.0L 6 Cyl Gas Engines J=Dana 35 Rear Axle---DRK=Dana 44 Rear Axle PUMP, Power Steering 52087 871AD 5208 8018 52087 713AB RESERVOIR, Power Steering Pump 4694 766 CAP, Power Steering Pump JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 337 6502 425 Pump Mounting M8x1.25x95.00 Pump Mounting M8x1.25x95.00 Pump Mounting M8x1.25x95.00 Pump Mounting M8x1.25x95.00 5301 0258 EP0, PULLEY, Power Steering Pump, Power Steering JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 338 6502 425 Pump Mounting M8x1.25x95.00 Pump Mounting M8x1.25x95.00 Pump Mounting M8x1.25x95.00 Pump Mounting M8x1.25x95.00 5301 0258 EP0, PULLEY, Power Steering Pump, Power Steering JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 339 52087 713AB RESERVOIR, Power Steering Pump 6502 425 EP0, SCREW AND WASHER, Hex Head, M8x1.25x95 # 53010 258AB EP0, PULLEY, Power Steering Pump JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 340 CAP, Power Steering Pump, Reservoir SCREW AND WASHER, Hex Head, M8x1.25x95 6502 425 CLAMP, Hose 2448 761 5301 0258 EP0, PULLEY, Power Steering Pump JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 341 CAP, Power Steering Pump SCREW AND WASHER, Hex Head, M8x1.25x95 6502 425 CLAMP, Hose 2448 761 5301 0258 EP0, PULLEY, Power Steering Pump JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 342 6502 425 EP0, SCREW AND WASHER, Hex Head, M8x1.25x95 CLAMP, Hose 2448 761 # 53010 258AB EP0, PULLEY, Power Steering Pump JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 343 GROUP 30RH - Automatic Transmission 3 Speed Illustration Title Group-Fig. No. Transmission Assembly Transmisson 30RH (DGD) ............Fig.
  • Page 344 Transmission, K4736388 Converter, K6501099 Bolts), 1997 TJ # 5013 401AA 52119811AA (package contains 52119811AA transmission, K4736388 Converter, K6501099 Bolts), 1999 TJ 5003 148AA Stamp# 52119520, 1998 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 345 1998 TJ, 1999 TJ 6028 095 PLUG, Pressure Check 6033 480 SNAP RING, Reverse Drum 4295 875 GASKET, Oil Pan SWITCH, Neutral, Safety, Back Up JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 346 MAGNET, Transmission 2408 143 WASHER, Switch 6033 616 SCREW, Hex Flange Head, .25-28x.875 5211 8595 SOLENOID, Transmission 5603 8235 CONNECTOR, Wiring JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 347 4471 874 1997 TJ 1998 TJ, 1999 TJ 4617 786 THRUST WASHER, Front Clutch 6023 943 SCREW AND WASHER, Hex Flange Head, .312- 18x1.375 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 348 1401 221 SEAL, Input Shaft 6022 859 SNAP RING, .890625 4028 333 SEAL, Rear Clutch, 1.50 ODx.009 Thk 4617 786 THRUST WASHER, Front Clutch JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 349 THRUST WASHER, Output Shaft, Gray .052 4505 186 THRUST WASHER, Output Shaft, Red .068 4505 187 THRUST WASHER, Output Shaft, Green .083 4617 157 BUSHING, Front Clutch JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 350 SCREW, Hex Flange Head, .25-28x.875 4637 956 DRUM PACKAGE, Transmission 4431 690 CAM, Overrunning Clutch 4431 432 CLUTCH, Overrunning 4617 775 PLATE, Annulus Gear Thrust JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 351 LEVER, Kickdown 4531 181 SHAFT, Band Lever 3515 084 STRUT, Kickdown Band 4617 849 BAND, Kickdown 0124 934 NUT, Hex Jam, .50-20 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 352 SNAP RING, 1.150" Free Diameter 4130 537 BEARING, Output Shaft 6032 739 O RING, Output Shaft Bearing, Transmission 6025 668 SNAP RING, 1.150" Free Diameter JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 353 4130 492 SPRING, Switch Valve BRACKET, (NOT SERVICED) 6030 609 SCREW, Cap Head Lock, .312-24x1.25 SCREW, (NOT SERVICED) 4348 907 SPRING, Limit Valve JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 354 Large, 1997 TJ 1998 TJ, 1999 TJ 3743 650 PISTON, Accumulator 3743 010 SEAL, Piston Accumulator 6031 410 O RING, Trans Kickdown Servo JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 355 SNAP RING, Transmission 2466 892 SHAFT, Parking Sprag 2466 906 ROD, Parking Sprag SPRING, Parking Sprag Return, (NOT SERVICED) 6035 256 SNAP RING, Rod JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 356 1997 TJ RHD, 1997 TJ 1998 TJ, 1999 TJ COVER, Gearshift 5300 0704 1997 TJ Shift Housing, 1998 TJ, 1999 TJ SCREW, Hex Self Tapping, .19-16x.50 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 357 .437-14, 1997 TJ, 1998 TJ 6028 114 1999 TJ SPRING, Pawl Return (NOT SERVICED), 1998 TJ, 1999 TJ 5300 3350 1997 TJ 1997 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 358 GROUP 32RH - Automatic Transmission 3 Speed Illustration Title Group-Fig. No. Transmission Assembly Transmission 32RH (DGG) ............Fig.
  • Page 359 52119525 (Package contains, 52119525 Transmission, K4736596 Converter, K1949765 Bolts), 1998 TJ # 5013 402AA 52119813AA (Package contains, 52119813AA transmission, K4736596 Converter, K1949765 Bolts), 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...

  • Page 360: Figure

    6033 479 BOLT, Hex Head, .25-28x1-5/8 3681 601 MAGNET, Transmission 2408 143 WASHER, Switch 6033 616 SCREW, Hex Flange Head, .25-28x.875 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 361 ENGINE TRANS DESCRIPTION 5211 8595 SOLENOID, Transmission 5603 8235 CONNECTOR, Wiring K018 1127 BOLT, Hex Head, .375-16x2.25 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 362 6033 479 BOLT, Hex Head, .25-28x1-5/8 3681 601 MAGNET, Transmission 2408 143 WASHER, Switch 6033 616 SCREW, Hex Flange Head, .25-28x.875 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 363 ENGINE TRANS DESCRIPTION 5211 8595 SOLENOID, Transmission 5603 8235 CONNECTOR, Wiring 0153 371 BOLT, Hex Head, .375-16x2.25 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 364 BOLT AND WASHER, Hex Head, .437-14x2.75 J021 9422 NUT, Hex 6033 157 STUD, .375-16x2.312 6033 479 BOLT, Hex Head, .25-28x1-5/8 3681 601 MAGNET, Transmission JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 365 6033 616 SCREW, Hex Flange Head, .25-28x.875 5211 8595 SOLENOID, Transmission 5603 8235 CONNECTOR, Wiring 0153 371 BOLT, Hex Head, .375-16x2.25 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 366 1998 TJ, 1999 TJ THRUST WASHER, Front Clutch 4617 786 1997 TJ, 1998 TJ 1999 TJ 6023 943 SCREW AND WASHER, Hex Flange Head, .312- 18x1.375 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 367 CHECK BALL, Dia-.187 SNAP RING, .890625 6022 859 ., 1997 TJ 1998 TJ, 1999 TJ 4028 333 SEAL, Rear Clutch, 1.50 ODx.009 Thk THRUST WASHER, Front Clutch JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 368 4505 186 THRUST WASHER, Output Shaft, Red .068 4505 187 THRUST WASHER, Output Shaft, Green .083 4617 157 BUSHING, Front Clutch 4617 159 BUSHING, Rear Clutch JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 369 Reverse, 1997 TJ 1998 TJ, 1999 TJ CAM, Overrunning Clutch 4431 690 Clutch, 1997 TJ 1998 TJ, 1999 TJ 4431 432 CLUTCH, Overrunning JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 370 PLUG, (NOT SERVICED) 2124 666 LEVER, Kickdown 4531 181 SHAFT, Band Lever 3515 084 STRUT, Kickdown Band 4617 849 BAND, Kickdown JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 371 Output Shaft Brg., 1-1/16" I.D., 1997 TJ 1998 TJ, 1999 TJ 4130 537 BEARING, Output Shaft 6032 739 O RING, Output Shaft Bearing, Transmission BOLT, Hex Head, .25-20x.68 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 372 SERIES ENGINE TRANS DESCRIPTION 6031 613 1997 TJ 1998 TJ, 1999 TJ 4883 956AA GASKET AND SEAL PACKAGE, Governor JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 373 SPRING, Switch Valve BRACKET, (NOT SERVICED) SCREW, Cap Head Lock, .312-24x1.25 6030 609 Throttle Pressure Adjusting, 1997 TJ 1998 TJ, 1999 TJ SCREW, .190-24 x 1‘‘ , (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 374 52118 740AB 1999 TJ 2801 274 SPRING, Reverse Servo Piston 2464 463 RETAINER, Transmission Rear Clutch 2464 464 SNAP RING SPRING, Accumulator JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 375 SEAL, Piston Accumulator 3743 010 Small, 1997 TJ 1998 TJ, 1999 TJ SPRING, Accumulator 3515 114 Upper, 1997 TJ 1998 TJ, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 376 1998 TJ, 1999 TJ 2466 892 SHAFT, Parking Sprag 2466 906 ROD, Parking Sprag SPRING, (NOT SERVICED) 6035 256 SNAP RING, Rod JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 377 RHD, 1997 TJ 1997 TJ, 1998 TJ 1998 TJ 1999 TJ J400 1701 SCREW, Hex Self Tapping, .19-16x.50 4641 780 STRAP, Tie JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 378 0152 476 1997 TJ, 1998 TJ 6028 114 1999 TJ SPRING, Pawl Return 5300 3350 RHD, 1997 TJ 1998 TJ, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 379 GROUP AISIN - Manual Transmission 5 Speed Illustration Title Group-Fig. No. Transmission Assembly Transmission (DDQ) 1997 TJ ........... . . Fig.
  • Page 380 ER0 = All 4.0L 6 Cyl Gas Engines J=Dana 35 Rear Axle---DRK=Dana 44 Rear Axle DDQ = Manual Transmission 5 Speed J=Dana 35 Rear Axle---DRK=Dana 44 Rear Axle TRANSMISSION, 5 Speed 5210 8117 5210 8118 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE...
  • Page 381 ER0 = All 4.0L 6 Cyl Gas Engines J=Dana 35 Rear Axle---DRK=Dana 44 Rear Axle DDQ = Manual Transmission 5 Speed J=Dana 35 Rear Axle---DRK=Dana 44 Rear Axle TRANSMISSION, 5 Speed 5210 4548 52108 118AB JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE...
  • Page 382 ER0 = All 4.0L 6 Cyl Gas Engines J=Dana 35 Rear Axle---DRK=Dana 44 Rear Axle DDQ = Manual Transmission 5 Speed J=Dana 35 Rear Axle---DRK=Dana 44 Rear Axle TRANSMISSION, 5 Speed 5210 4548 52108 118AB JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE...
  • Page 383 3420 1818 SCREW, Hex Head, M8x1.25x25 4746 025 RETAINER, Bearing 8350 0505 GASKET, Input Gear Retainer 8350 6045 SEAL, Main Shaft JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 384 8350 0631 CLAMP, Transmission 8350 3551 CLAMP, Transmission 8350 0632 GASKET, Transmission PIN, Locating 8350 0539 1998 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 385 3420 1818 1998 TJ 1999 TJ 4746 025 RETAINER, Bearing 8350 0505 GASKET, Input Gear Retainer 8350 6045 SEAL, Main Shaft JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 386 3420 1818 SCREW, Hex Head, M8x1.25x25 8350 3109 CAP, Detent 8350 0623 PLUG, Oil Fill 5252 036 RETAINER, Output Shaft Rear Bearing JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 387 3420 1818 1998 TJ 1999 TJ CAP, Detent 8350 3109 1998 TJ 1999 TJ 8350 0623 PLUG, Oil Fill JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 388 PART ITEM NUMBER LINE SERIES ENGINE TRANS DESCRIPTION 5252 036 RETAINER, Output Shaft Rear Bearing JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 389 BEARING, First Gear 8350 0573 BALL, Reverse 8350 6026 RACE, First Gear 8350 6030 BEARING, Mainshaft 8350 0613 SNAP RING JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 390 8350 6022 GEAR, Countershaft Fifth 8350 6024 GEAR, Fifth Splined 4746 657 SLEEVE, Synchronizer 4897 110AA SPRING, Compression 4897 109AA JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 391 DESCRIPTION 4897 112AA RING, Snap 4897 108AA PLATE, Transmission Idler Shaft 4897 111AA RING, Transmission 4897 107AA RACE, Idler Gear JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 392 BEARING, First Gear 8350 0573 BALL, Reverse 8350 6026 RACE, First Gear 8350 6030 BEARING, Mainshaft 8350 0613 SNAP RING JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 393 4897 109AA 4897 112AA RING, Snap 4897 108AA PLATE, Transmission Idler Shaft 4897 111AA RING, Transmission 4897 107AA RACE, Idler Gear JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 394 BALL, Reverse 8350 6026 RACE, First Gear 8350 6030 BEARING, Mainshaft 8350 0613 SNAP RING 8350 0971 GEAR, Fifth JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 395 4897 109AA 4897 112AA RING, Snap 4897 108AA PLATE, Transmission Idler Shaft 4897 111AA RING, Transmission 4897 107AA RACE, Idler Gear JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 396 8350 6252 STOP RING, Synchronizer, 1st & 2nd Gear, No. 1 8350 6254 SPRING, Synchronizer Key, Shifting Key 8350 6247 HUB, Synchronizer, Clutch Hub #1, 1st and 2nd Gear JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 397 Stamped I (X=3.15mm/3.20mm) 8350 6277 Stamped J (X=3.20mm/3.25mm) 8350 6278 Stamped K (X=3.25mm/3.30mm) 8350 6279 Stamped L (X=3.30mm/3.35mm) 8350 0646 PIPE, Oil Receiver JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 398 8350 6247 HUB, Synchronizer 8350 6250 KEY, Synchronizer SNAP RING 8350 6093 Stamped B (x=2.35mm/2.40mm) 8350 6094 Stamped C (x=2.40mm/2.45mm) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 399 Stamped L (x=3.15mm/3.20mm) 8350 6277 Stamped M (x=3.20mm/3.25mm) 8350 6278 Stamped N (x=3.25mm/3.30mm) 8350 6279 Stamped P (x=3.30mm/3.35mm) 8350 0646 PIPE, Oil Receiver JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 400 STAMPED B (X=2.35mm/2.40mm) 8350 6094 STAMPED C (X=2.40mm/2.45mm) 8350 6095 STAMPED D (X=2.45mm/2.50mm) 8350 6096 STAMPED E (X=2.50mm/2.55mm) 8350 6097 STAMPED F (X=2.55mm/2.60mm) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 401 STAMPED I (X=3.15mm/3.20mm) 8350 6277 STAMPED J (X=3.20mm/3.25mm) 8350 6278 STAMPED K (X=3.25mm/3.30mm) 8350 6279 STAMPED L (X=3.30mm/3.35mm) 8350 0646 PIPE, Oil Receiver JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 402 8350 0610 SNAP RING, Input Shaft, 2.25mm 8350 0611 SNAP RING, Input Shaft, 2.30mm GEAR, Countershaft 4636 371 4796 003 1997 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 403 8350 0568 1998 TJ STOP RING, Synchronizer 4637 533 No. 3, 5th Gear, 1997 TJ No. 3, 5th Gear, 1997 TJ 8350 0566 1998 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 404 4874 506 Stamped E (x=2.95mm/3.00mm) 4874 507 Stamped F (x=3.00mm/3.05mm) 4874 508 Stamped G (x=3.05mm/3.10mm) 4874 509 Stamped H (x=3.10mm/3.15mm) BALL, Reverse JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 405 ITEM NUMBER LINE SERIES ENGINE TRANS DESCRIPTION 8350 0573 1997 TJ 1998 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd. Auto.
  • Page 406 4874 503 STAMPED A (X=2.80mm/2.85mm) 4874 504 STAMPED B (X=2.85mm/2.90mm) 4874 505 STAMPED C (X=2.90mm/2.95mm) 4874 506 STAMPED E (X= 2.95mm/3.00mm) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 407 DESCRIPTION 4874 507 STAMPED F (X=3.00mm/3.05mm) 4874 508 STAMPED G (X=3.05mm/3.10mm) 4874 509 STAMPED H (X=3.10m/3.15mm) 8350 0573 BALL, Reverse JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 408 8350 3107 BOLT 8350 0525 BOLT AND LOCK WASHER, Hex Head, M8x1. 25x30 4882 436 LEVER, Gearshift 8350 0520 BOOT, Gearshift JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 409 ENGINE TRANS DESCRIPTION 8350 0519 BUSHING, Shift Lever 8350 3109 CAP, Detent 4864 216 SHIELD, Transmission JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 410 8350 0525 BOLT 8350 3107 BOLT AND LOCK WASHER, Hex Head, M8x1. 25x30 4882 436 LEVER, Gearshift 8350 0520 BOOT, Gearshift JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 411 ENGINE TRANS DESCRIPTION 8350 0519 BUSHING, Shift Lever 8350 3109 CAP, Detent 4864 216 SHIELD, Transmission JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 412 4864 211 RETAINER, Transmission 8350 3107 BOLT 8350 0525 BOLT AND LOCK WASHER, Hex Head, M8x1. 25x30 4882 436 LEVER, Gearshift JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 413 DESCRIPTION 8350 0520 BOOT, Gearshift 8350 0519 BUSHING, Shift Lever 8350 3109 CAP, Detent 4864 216 SHIELD, Transmission JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 414 RETAINER, Transmission Control Shift 8350 0525 BOLT AND LOCK WASHER, Hex Head, M8x1. 25x30 5252 211 BOLT, Gearshift Retainer, M8x1.25x50.4MM 4882 436 LEVER, Gearshift JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 415 RETAINER, Transmission Control Shift 8350 0525 BOLT AND LOCK WASHER, Hex Head, M8x1. 25x30 5252 211 BOLT, Gearshift Retainer 4882 436 LEVER, Gearshift JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 416 RETAINER, Transmission Control Shift 8350 0525 BOLT AND LOCK WASHER, Hex Head, M8x1. 25x30 5252 211 BOLT, Gearshift Retainer 4882 436 LEVER, Gearshift JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 417 5207 8971 COVER, Floor Pan BEZEL, Gearshift Lever Boot 5300 0056 1998 TJ Holds upper Boot In Console, 1997 TJ 3420 1035 RIVET, M4x12 Aluminum JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 418 1150 2843 SCREW, Hex Flange Head, M4.2x1.41x13.00 5207 8971 COVER, Floor Pan 5300 0056 BEZEL, Gearshift Lever Boot 3420 1035 RIVET, M4x12 Aluminum JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 419 GROUP 231 - Transfer Case Model 231 Illustration Title Group-Fig. No. Transfer Case Assembly Transfer Case Command Trac (DHN) ..........Fig.
  • Page 420 5209 9310 1998 TJ 5209 9211 EP0, 1999 TJ 5209 9364 1999 TJ 52111 005AA 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 421 1997 TJ, 1999 TJ 1998 TJ 1998 TJ EP0, 1999 TJ 1999 TJ NUT AND CONED WASHER, Hex, .375-24 J400 6681 1997 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 422 BOLT, Transfer Case 4210 617 Case Half, 1997 TJ EN0, Case Half, 1997 TJ Case Half, 1998 TJ Case Half, 1998 TJ Case Half, 1998 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 423 1997 TJ 1997 TJ, 1998 TJ 1998 TJ EP0, 1999 TJ 1999 TJ VENT, Transfer Case 5300 7494 1997 TJ, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 424 1998 TJ, 1999 TJ EP0, 1999 TJ WASHER, Flat 4210 983 1997 TJ 1997 TJ EN0, 1997 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 425 1997 TJ EN0, 1997 TJ 1997 TJ, 1999 TJ 1998 TJ 1998 TJ EP0, 1999 TJ BRACKET, Tube JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 426 Oil, 1998 TJ Oil, 1998 TJ Oil, 1998 TJ, 1999 TJ EP0, 1999 TJ CONNECTOR, Oil Tube Pickup 4338 944 EN0, 1997 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 427 EN0, Rear Bearing O.D. Retaining, 1997 TJ Rear Bearing O.D. Ret, 1998 TJ Rear Bearing O.D. Ret, 1998 TJ Rear Bearing O.D. Ret, 1998 TJ EP0, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 428 1999 TJ 1999 TJ SLINGER, Oil 4798 119 EN0, 1997 TJ 1997 TJ, 1998 TJ 1997 TJ, 1999 TJ 1998 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 429 EN0, 1997 TJ 1997 TJ, 1998 TJ 1997 TJ, 1999 TJ 1998 TJ 1998 TJ EP0, 1999 TJ 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 430 EP0, 1999 TJ SEAL, Main Shaft 4210 603 1997 TJ 1997 TJ EN0, 1997 TJ Oil, 1998 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 431 BEARING, Input Shaft 8350 3507 1997 TJ 1997 TJ EN0, 1997 TJ Pilot, 1998 TJ Pilot, 1998 TJ Pilot, 1998 TJ, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 432 Snap, Planetary Carrier, 1998 TJ, 1999 TJ EP0, 1999 TJ SNAP RING 4338 933 1997 TJ Retaining, 1998 TJ Retaining, 1998 TJ Retaining, 1998 TJ, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 433 Drive, 1998 TJ Drive, 1998 TJ, 1999 TJ EP0, 1999 TJ SNAP RING 3821 558 EN0, 1997 TJ Snap Bearing Retaining, 1998 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 434 1997 TJ 1997 TJ EN0, 1997 TJ Output, 231 Transfer Case, 1998 TJ Output, 231 Transfer Case, 1998 TJ Output, 231 Transfer Case, 1998 TJ, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 435 Yoke, Front Output Shaft, With Slinger, 1998 TJ Yoke, Front Output Shaft, With Slinger, 1998 TJ Yoke, Front Output Shaft, With Slinger, 1998 TJ EP0, 1999 TJ WASHER, Flat JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 436 1997 TJ EN0, 1997 TJ 1997 TJ, 1999 TJ Input, 1998 TJ Input, 1998 TJ Input, 1998 TJ EP0, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 437 1997 TJ 1998 TJ, 1999 TJ 1998 TJ, 1999 TJ 1998 TJ, 1999 TJ FORK, Transfer Case Mode Shift 4741 237 1997 TJ 1997 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 438 4638 845 1997 TJ 1997 TJ EN0, 1997 TJ Transfer Case Shifting, 1998 TJ Transfer Case Shifting, 1998 TJ Transfer Case Shifting, 1998 TJ, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 439 1997 TJ EN0, 1997 TJ Sector Seal, 1998 TJ Sector Seal, 1998 TJ Sector Seal, 1998 TJ, 1999 TJ EP0, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 440 1998 TJ, 1999 TJ LEVER, Transfer Case Shifter 53005 150AB RHD, 1997 TJ 1998 TJ, 1999 TJ GROMMET, Control Rod Front 3575 333 RHD, 1997 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 441 J941 9683 1997 TJ, 1999 TJ 3420 1381 SCREW, Hex Flange Head Tapping, M6x1.00x20.00 6504 601 NUT, Rivet Round, M5x0.80x11.09 5210 4014 GROMMET JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 442 GROUP 21P - Speedometer Pinions Illustration Title Group-Fig. No. Speedometer Pinions Speedometer Pinion And Housing 1997 TJ ......... . . Fig.
  • Page 443 5206 7639 4.11 AXLE RATIO, 39 Teeth, All 225/245 Tires 5206 7640 4.11 AXLE RATIO, 40 Teeth, ALL 215 Tires. 5206 7641 4.11 AXLE RATIO, 41 Teeth, All 205 Tires. JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 444 5206 7639 4.11 AXLE RATIO, 39 Teeth, All 225/245 Tires 5206 7640 4.11 AXLE RATIO, 40 Teeth, ALL 215 Tires. 5206 7641 4.11 AXLE RATIO, 41 Teeth, All 205 Tires. JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 445 4.11 AXLE RATIO, 39 Teeth,All 225/245 Tires 5206 7640 4.11 AXLE RATIO, 40 Teeth, All 215 Tires. P2225/70R16 BSW VSB All. 5206 7641 4.11 AXLE RATIO, 41 Teeth, All 205 Tires. JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION...
  • Page 446 GROUP 22 - Wheels, Covers and Jacks Illustration Title Group-Fig. No. Wheels and Hardware Wheels 1997 TJ 1998 TJ ............Fig.
  • Page 447 15x8 Aluminum (TBB+WJH), 1998 TJ 5208 8157 15x7 [WJ9], 1997 TJ 15x8 Aluminum (TBB+WJ9), 1998 TJ NUT, Wheel, .50x20 J400 6956 1997 TJ Capped Wheel, 1998 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 448 # 5GC81 TAEAA 4 WHEEL, Aluminum, 15x8 Aluminum (WJX) 5FG5 6PAK WHEEL, Aluminum, Stamped USA, 5FG56PAKAB Stamped Italy, 16x7 Aluminum (WDU) J400 6956 NUT, Wheel, .50x20, Capped Wheel JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 449 [WJ1], 1998 TJ CAP, Wheel Center 5208 9008 WJK, 1997 TJ 5CF3 4L4A WJ5, 1997 TJ 5208 9008 [WJK], 1998 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 450 5DY0 7TAE [WJ1] 5CF3 4L4A [WJ5] 5200 2971 [WJ9] 5208 9008 CAP, Wheel Center, [WJK] 5CF9 7L3X CAP, Wheel Center, Brushed Aluminum "Jeep" Name, [WJX] JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 451 5205 8907 1997 TJ 1997 TJ 1998 TJ, 1999 TJ 5205 9047 STRAP, Jack Tool Storage 6504 697 CLIP, Lug Wrench JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 452 Spice with ‘SAHARA‘ Europe 5FF4 7TX7 Black 5FF5 5TX7 Black with Insert 5FF5 7TTB Spice with ‘SAHARA‘ 6034 949 SCREW JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 453 Spice, ‘Sahara‘ Europe 5FF4 7TX7 Black 5FF5 5TX7 Black, ‘Sahara‘ Black, ‘Sahara‘ Europe 5FF5 7TTB Spice, ‘Sahara‘ SCREW, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 454 Spice, ‘Sahara‘ Europe 5FF4 7TX7 Black, 5FF5 5TX7 Black, ‘Sahara‘ Black, ‘Saraha‘ Europe 5FF5 7VK9 Spice, ‘Sahara‘ SCREW, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 455 GROUP 23D - Wiper/Lock Cylinder and Keys Illustration Title Group-Fig. No. Lock Cylinders and Keys Lock Cylinders And Keys 1997 TJ ..........Fig.
  • Page 456 5257 134 TUMBLER, Ignition Number 3, use with console and glove box cylinders 5257 135 TUMBLER, Ignition Number 4, use with console and glove box cylinders TRANSMITTER, Anti Theft JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 457 Mandatory ( EUROPEAN, SOUTH AFRICA, UNITED KINGDOM,)Not Available in ( POLAND, RUSSIA, ROMANIA, BULGARIA, SLOVENIA), Mandatory (EUROPEAN, SOUTH AFRICA, UNITED KINGDOM, )Not Available in (POLAND, RUSSIA, ROMANIA, BULGARIA, SLOVENIA) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 458 TUMBLER, Ignition Number 1, Console 5257 133 TUMBLER, Ignition Number 2, Console 5257 134 TUMBLER, Ignition Number 3, Console 5257 135 TUMBLER, Ignition Number 4, Console JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 459 TUMBLER, Ignition Number 3, use with console and glove box cylinders 5257 135 TUMBLER, Ignition Number 4, use with console and glove box cylinders 4778 148 CYLINDER, Deck Lid Lock JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...

  • Page 460: Figure

    TEE, Washer Hose, Connector 4805 010 CHECK VALVE, Washer 5288 255 CLIP, Hood Washer Hose, Fastener MOTOR, Wiper 4864 892 Windshield Wiper Windshield Wiper JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 461 TEE, Washer Hose 4805 010 CHECK VALVE, Washer 5288 255 CLIP, Hood Washer Hose MOTOR, Wiper 4864 892 Windshield Wiper Windshield Wiper JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 462 TEE, Washer Hose 4805 010 CHECK VALVE, Washer 5288 255 CLIP, Hood Washer Hose MOTOR, Wiper 4864 892 Windshield Wiper Windshield Wiper JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 463 PLUG, Sealing, Tether (Hard Top) 5515 4545 WASHER, Between Gass & Motor 5515 4556 SPACER, Wiper Motor, Triangle Shaped 5600 3682 NUT, Hex Flange, M16 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 464 PLUG, Sealing, Tether (Hard Top) 5515 4545 WASHER, Between Gass & Motor 5515 4556 SPACER, Wiper Motor, Triangle Shaped 5600 3682 NUT, Hex Flange, M16 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 465 5600 3982 PLUG, Sealing 5515 4545 WASHER, Between Glass & Motor 5515 4556 SPACER, Wiper Motor, Triangle Shaped 5600 3682 NUT, Hex Flange, M16 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 466 GROUP 24 - Air Conditioning & Heater Illustration Title Group-Fig. No. Air Conditioner and Heater Units Hevac Unit 1997 TJ 1998 TJ ........... . . Fig.
  • Page 467 Blower ***, 1997 TJ 1998 TJ 1998 TJ DOOR, Blend Air 4864 958 Blend Air, 1997 TJ 1998 TJ 4864 988 1997 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 468 4864 999AB 1998 TJ 4874 044 1997 TJ 4874 044AB 1998 TJ CORE, Heater 4874 045 Heater Core, 1997 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 469 1997 TJ 1998 TJ WIRING, Air Conditioning Module 4886 085AA 1997 TJ 1997 TJ 1998 TJ 1998 TJ DUCT, Floor Distribution JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 470 1998 TJ 1998 TJ 4886 086AB LEVER, Panel Door 5014 108AA LEVER, Defroster Door DOOR, Defroster, Serviced With Upper Housing Only, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 471 5013 741AA Electric ADAPTER, Blend Door, A/C and Heater 5013 742AA 5013 743AA 5013 745AA BRACKET, Blend Door Adapter, A/C and Heater ACTUATOR, Vacuum JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 472 DUCT, Floor Distribution 4874 088 4874 089 SCREW, Hex Head, M4.8-1.59x19 4734 227 SCREW 9419 322 CLIP, A/C Heater Housing 4644 388 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 473 Figure 024-110 PART ITEM NUMBER LINE BODY ENGINE DESCRIPTION CLIP, Air Conditioning, 25mm Diameter 4644 127 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 474 1997 TJ, 1998 TJ BRACKET, Hose 5503 5933 Hose, 1997 TJ Hose, 1997 TJ EP0, 1998 TJ, 1999 TJ EP0, 1998 TJ, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 475 1997 TJ 1997 TJ, 1998 TJ BRACKET, Hose 5503 5933 Hose, 1997 TJ Hose, 1997 TJ EP0, 1998 TJ, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 476 CLAMP, Hose, M28.9 x 1.60 6502 018 1997 TJ BRACKET, Hose 5503 5933 Hose, 1997 TJ 1998 TJ Hose, 1997 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 477 5503 6345 HOSE, Heater Return 5503 6976 HOSE, Heater, Supply 6502 017 CLAMP, Heater Hose 5503 5933 EP0, BRACKET, Hose JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 478 1997 TJ 1997 TJ, 1998 TJ BRACKET, Hose 5503 5933 Hose, 1997 TJ Hose, 1997 TJ EP0, 1998 TJ, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 479 5503 6730 EP0, TUBE, A/C Liquid Line 5503 6731 EP0, LINE, A/C Discharge 4883 839AA EP0, ORIFICE, Liquid Line JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 480 LABEL, Refrigerant, Charge 4596 153 CLIP, A/C Quick Disconnect, Quick (Suction) Connect 4596 153 CLIP, A/C Quick Disconnect, Quick (Discharge) Connect 4883 839AA EP0, ORIFICE, Liquid Line JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 481 5503 6352 LABEL, Refrigerant, Charge CLIP, A/C Quick Disconnect 4596 152 4596 153 Quick (Suction) Connect 4596 153 CLIP, A/C Quick Disconnect, (Discharge) Connect JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 482 5503 6304 BRACKET, Accumulator, Accumulator Mtg. 55036 206AB BAND, Accumulator Retaining, Accumulator Support SCREW, (NOT SERVICED) 5503 6294 EP0, ACCUMULATOR, Suction Line JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 483 NUT, (NOT SERVICED) 5503 6304 BRACKET, Accumulator 55036 206AB BAND, Accumulator Retaining, Support SCREW, (NOT SERVICED) 55036 294AB EP0, ACCUMULATOR, Suction Line JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 484 5503 6304 BRACKET, Accumulator 55036 206AB BAND, Accumulator Retaining, Accumulator Support SCREW, (NOT SERVICED) # 55037 442AA EP0, ACCUMULATOR, Suction Line JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 485 SCREW, (NOT SERVICED) 5264 642 CAP, A/C Check Valve 4883 839AA EP0, ORIFICE, Liquid Line 4761 737 O RING, A/C Suction Line JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 486 55036 293AB EP0, ACCUMULATOR, Suction Line 4897 614AA EP0, SWITCH, A/C Cycling 55036 206AB BAND, Accumulator Retaining, Support SCREW, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 487 CLIP, A/C Quick Disconnect # 55037 440AA ACCUMULATOR, Suction Line 4897 614AA SWITCH, A/C Cycling 55036 206AB BAND, Accumulator Retaining, Accumulator Support SCREW, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 488 CLIP, A/C Quick Disconnect 5503 6367 EP0, CONDENSER, Air Conditioning NUT, (NOT SERVICED) SCREW, (NOT SERVICED) 4761 737 O RING, A/C Suction Line JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 489 VALVE, A/C Discharge Line Check 4596 152 CLIP, A/C Quick Disconnect 55036 367AB EP0, CONDENSER, Air Conditioning NUT, (NOT SERVICED) SCREW, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 490 VALVE, A/C Discharge Line Check 4596 152 CLIP, A/C Quick Disconnect # 55037 483AC EP0, CONDENSER, Air Conditioning NUT, (NOT SERVICED) SCREW, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 491 Condenser to Grille, 1998 TJ 6030 441 PIN, Retainer, Push SEAL, Condenser 5503 6369 Lower, 1997 TJ Lower, 1997 TJ Lower, 1998 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 492 # 55036 866AC SEAL, Condenser 5503 6867 SEAL, Condenser, Condenser to Grille 6030 441 PIN, Retainer, Push 5503 6369 SEAL, Condenser, Lower JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 493 1998 TJ 55037 393AA EP0, 1997 TJ 55037 393AC EP0, 1998 TJ J400 6866 NUT, Push On JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 494 5503 5614 RESERVOIR, Vacuum, Cruise Control 6034 205 SCREW, Pan Head, .19-32x.625 6034 949 SCREW, M4.2x1.69x19.05 5011 214AA SWITCH, Blower Control JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 495 CLUTCH, A/C Compressor 4882 005 EP0, Compressor, 1998 TJ EP0, With 55037205 Compressor, 1997 TJ 4882 004 EP0, With 55037358 Compressor, 1997 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 496 4720 834 EP0, PULLEY HUB KIT, A/C Compressor 5264 454 EP0, SNAP RING KIT, A/C Clutch 8230 0102 EP0, LUBRICANT, Oil, 75w90 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 497 ADAPTER, Demister 5503 6308 5503 6309 5511 5157 DUCT, Fresh Air COLLAR, Plenum 5503 6474 Plenum Panel Air Inlet 5503 6497 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 498 ADAPTER, Demister 5503 6308 5503 6309 5511 5157 DUCT, Fresh Air COLLAR, Plenum 5503 6474 Plenum Panel Air Inlet 5503 6497 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 499 GROUP 25 - Emission Systems Illustration Title Group-Fig. No. Emission Labels Emission Labels 2.5L (EPE), 4.0L (ERH) Engine ........Fig.
  • Page 500 # 53031 828AA Europe, 1999 TJ # 53031 829AA Federal, 1999 TJ # 53031 831AA California, 1999 TJ # 53031 832AA Europe, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 501 6035 399 EP0, SCREW, .25-20 0153 355 EP0, U-NUT, .25-20 4192 074 EP0, CAP, Vapor Canister JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 502 EP0, GROMMET, Air Cleaner Bracket 6101 452 EP0, SCREW AND WASHER, Hex Head, M8x1.25x20 6101 467 EP0, NUT, Hex Flange, M8x1.25 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 503 HARNESS, Vacuum Canister Purge 4854 160 4854 163 1997 TJ, 1998 TJ # 4854 163AB Leaded Fuel, 1999 TJ # 4854 134AC Federal, California, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 504 EP0, SCREW, Tapping, .19-16x.375 HOSE, Leak Detection Pump to Canister 4854 195AB EP0, 1998 TJ # 4854 195AC EP0, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 505 GROUP DTJ - Doors and Related Parts Illustration Title Group-Fig. No. Front Door Door, Full Front Shell And Hinges 1997 TJ ......... . . Fig.
  • Page 506 55176 568AB Sail, Right 55176 569AB Sail, Left SCREW, (NOT SERVICED) 55175 848AB BRACKET, Grab Handle, Grab Handle SCREW, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 507 Door, Full Front Shell And Hinges 1997 TJ Figure DTJ-110 PART ITEM NUMBER LINE SERIES BODY DESCRIPTION 6504 993AA JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 508 Sail, Right 55176 569AB Sail, Left SCREW, (NOT SERVICED) 55175 848AB BRACKET, Grab Handle, Grab Handle SCREW, (NOT SERVICED) 6504 993AA JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 509 55176 568AB Sail, Right 55176 569AB Sail, Left SCREW, (NOT SERVICED) # 55175 848AC BRACKET, Grab Handle SCREW, (NOT SERVICED) 6504 993AA JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 510 Regulator Handle, 1997 TJ Regulator Handle, 1997 TJ 1998 TJ, 1999 TJ HANDLE, Window Regulator FW80 PX9 Glass, 1997 TJ Glass Regulator, 1998 TJ, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 511 5517 6629 Left LINK, Door Latch 5517 6630 Right 5517 6631 Left 4673 358 CLIP, Anti Rattle JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 512 55176 629AB Left LINK, Door Latch 5517 6630 Right 5517 6631 Left 55177 131AA BRACKET, Door Inside JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 513 55176 628AB Right 55176 629AB Left LINK, Door Latch 5517 6630 Right 5517 6631 Left JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 514 J545 9281 Tapping Tapping J545 9286 PIN, Restraint Strap 6504 993AA 55175 849AB BRACKET, Grab Handle SCREW, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 515 J545 9286 PIN, Restraint Strap 6504 993AA 55175 849AB BRACKET, Grab Handle SCREW, (NOT SERVICED) 5501 3666 FOOTMAN LOOP, Hold Down JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 516 J545 9281 TAPPING PLATE, Door Hinge Body Half J545 9286 PIN, Restraint Strap 6504 993AA 55175 849AC BRACKET, Grab Handle SCREW, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 517 Exterior Handle to Latch, Right Exterior Handle to Latch, Right 5507 5977 Exterior Handle to Latch, Left Exterior Handle to Latch, Left 6503 998 NUT, U Multi Thread, M5 x .80 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 518 5517 6626 Right 5517 6627 Left LINK, Door Latch 5517 6624 Right 5517 6625 Left JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 519 5517 6626 Right 5517 6627 Left LINK, Door Latch 5517 6624 Right 5517 6625 Left JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 520 5515 5045 GRV, 1997 TJ, Left 5515 5588 Middle East, Right 5515 5589 Middle East, Left 6034 566 SCREW, Tapping Flange Head, .25-20x.875, Mirror JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 521 55254 895AC Left WEATHERSTRIP, Glass Channel Run 5517 5226 Weatherstrip Weatherstrip 5517 5750 Channel Channel JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 522 55254 894AC Right 55254 895AC Left WEATHERSTRIP, Glass Channel Run 55175 226AB Weatherstrip 55175 750AB Channel JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 523 55175 226AB Weatherstrip 55175 750AB Channel WATERSHIELD, Front Door # 55175 786AD Right # 55175 787AD Left JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 524 GROUP ETJ - Exterior Ornamentation Illustration Title Group-Fig. No. Moldings and Ornamentation Mouldings ..............Fig.
  • Page 525 Air, 1997 TJ, Right 1998 TJ, 1999 TJ, Right 5503 6307 1997 TJ, Left 1998 TJ, 1999 TJ, Left SCREW, (NOT SERVICED) NUT, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 526 DECAL, 4.0L High Output 5FC8 5TA2 [KYP] 5FC8 5TA9 [KYR] 5FE5 2TVJ DECAL, Sahara, [KBJ] 5515 5566 PROTECTOR, Door Opening, Lower Door JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 527 DECAL, 4.0L High Output 5FC8 5TA2 [KYP] 5FC8 5TA9 [KYR] 5FE5 2WGK DECAL, Sahara, [KBT] 5515 5566 PROTECTOR, Door Opening, Lower Door JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 528 Fig. ITJ-610 Seat Assemblies, Seat Covers Rear Seat Wrangler 1999 TJ ......
  • Page 529 Agate, After 2-17-97, 1997 TJ, Left,Export 5FP03 LAZAD Agate, Up to 5-13-98, 1998 TJ, Left,Export 5FP03 LAZAE Agate, After 5-13-98, (With Passenger Disarm Label), 1998 TJ Agate, 1999 TJ, Left JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 530 (NOT REQUIRED), 1997 TJ 4787 437AA English/French 5 Points, 1998 TJ, 1999 TJ 55315 001AA CANADA, Passenger Disarm Warning, 1998 TJ CANADA, Passenger Airbag Disarm Warning, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 531 5521 7099 COVER, Contact Button, Chmsl Contact Button Bracket SCREW, .164-18x.500, (NOT SERVICED) 6503 274 NUT, Push On 5521 7379 NET, Cargo, Cargo JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 532 Saddle, Left COVER, Wheelhouse Carpet, (NOT REQUIRED) 5521 7099 COVER, Contact Button, Chmsl Contact Button Bracket SCREW, .164-18x.500, (NOT SERVICED) NUT, Push On 6503 274 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 533 PART ITEM NUMBER LINE SERIES BODY TRIM DESCRIPTION 5521 7379 NET, Cargo, Cargo JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd. Auto.
  • Page 534 5FV17 VK9AC Tan, Left COVER, Wheelhouse Carpet, (NOT REQUIRED) 5521 7099 COVER, Contact Button SCREW, .164-18x.500, (NOT SERVICED) NUT, Push On 6503 274 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 535 Mist Gray, Right 5DY6 6TT6 Saddle, Right 5DY6 7TC3 Mist Gray, Left 5DY6 7TT6 Saddle, Left 6035 747 SCREW, M4.2-1.41x13 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 536 Mist Gray, Right 5DY6 6TT6 Saddle, Right 5DY6 7TC3 Mist Gray, Left 5DY6 7TT6 Saddle, Left 6035 747 SCREW, M4.2-1.41x13 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 537 Camel, Right 5DY6 6LAZ Agate, Right 5DY6 71K5 Camel, Left 5DY6 7LAZ Agate, Left 6035 747 SCREW, M4.2-1.41x13 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 538 PY63 TT6 Saddle, With Easy Entry, Driver,Export Saddle, With Easy Entry, Driver,Export PY66 TC3 Mist Gray, Passenger Mist Gray, Passenger PY66 TT6 Saddle, Passenger JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 539 Left 5012 160AA Right 5012 161AA Left 5012 160AA Right Right 5012 161AA Left JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd. Auto.
  • Page 540 NUMBER LINE SERIES BODY TRIM DESCRIPTION 6502 137 BOLT, Hex Flange Head, M10x1.50x35, Cushion to Frame JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 541 Mist Gray, With Easy Entry, Driver,Export Mist Gray, With Easy Entry, Driver,Export Mist Gray, With Easy Entry, Driver,Export Mist Gray, With Easy Entry, Driver,Export SG79 1T6AA Saddle, With Easy Entry, Driver,Export JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION...
  • Page 542 U-NUT, Seat Back 4713 982 Without Easy Entry Without Easy Entry Without Easy Entry Without Easy Entry 4874 145 With Easy Entry JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 543 Right Right 5012 161AA Left Left Left Left 6502 137 BOLT, Hex Flange Head, M10x1.50x35 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 544 Camel, With Easy Entry, Driver,Export Camel, With Easy Entry, Driver,Export Camel, With Easy Entry, Driver,Export Camel, With Easy Entry, Driver,Export SG80 1KGAA Moss, Passenger SG81 1KGAA Moss, Driver JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 545 Without Easy Entry 4874 145 With Easy Entry With Easy Entry With Easy Entry With Easy Entry FRAME, Front Seat 5012 160AA Right JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 546 5012 161AA Left 5012 160AA Right Right 5012 161AA Left 6502 137 BOLT, Hex Flange Head, M10x1.50x35 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 547 RH39 1C3AA Mist Gray, After 2-3-97 RH39 1T6AA Saddle, After 2-3-97 LEVER, Rear Seat Release 4713 794 RIVNUT, Seat Latch Cover 4728 280 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 548 Rear Seat Lock Striker, Right 5521 7129 Rear Seat Lock Striker, Left 6034 564 SCREW, Pan Head, .312-18x1 6504 571 PIN, Rear Seat, Spring Wire JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 549 SPRING, Seat Release Lever 4713 795 WASHER, Rear Seat Pivot, Black Nylon 4713 799 BOLT, Shoulder 4638 585 U-NUT, Seat Back, Used with Bolt 4638585 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 550 5521 7128 Rear Seat Lock Striker, Right 5521 7129 Rear Seat Lock Striker, Left 6034 564 SCREW, Pan Head, .312-18x1 6504 571 PIN, Rear Seat JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 551 Seat Assemblies, Seat Covers Rear Seat Wrangler 1999 TJ Figure ITJ-610 PART ITEM NUMBER LINE SERIES BODY TRIM DESCRIPTION Trim Code ‘‘D6‘‘ does not come with a rear seat. J=Dana 35 Rear Axle---DRK=Dana 44 Rear Axle COVER, Rear Seat Back...
  • Page 552 Seat Assemblies, Seat Covers Rear Seat Wrangler 1999 TJ Figure ITJ-610 PART ITEM NUMBER LINE SERIES BODY TRIM DESCRIPTION 4713 982 5519 6450 STRAP, Retaining 6500 664 SCREW AND WASHER, Hex Head, M8x1.25x35 BRACKET, Rear Seat Pivot 55217 130AB Right...
  • Page 553 Right,Export Right,Export BOLT, Seat Belt 4874 129 1997 TJ 1997 TJ 1997 TJ 1997 TJ 1998 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 554 6035 115 1997 TJ 1997 TJ 1997 TJ 1997 TJ 1998 TJ 1998 TJ 1998 TJ 1998 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 555 Seat Belts Wrangler 1999 TJ Figure ITJ-710 PART ITEM NUMBER LINE SERIES BODY TRIM DESCRIPTION SEAT BELT, Retractor 5EV70 LAZAB Right 5EV71 LAZAB Left 5EV72 LAZAB Right,Export 5EV73 LAZAB Left,Export 55217 173AB ADJUSTER, Seat Belt Turning Loop 5EZ7 0TAZ COVER, Turning Loop...
  • Page 556 Seat Belts Wrangler 1999 TJ Figure ITJ-710 PART ITEM NUMBER LINE SERIES BODY TRIM DESCRIPTION 6035 115 # 6036 294AA BOLT, Shoulder JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 557 4874 111 Shield to Seat Frame Shield to Seat Frame Shield to Seat Frame Shield to Seat Frame BOLT, Recliner to Seat Back 4720 768 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 558 Lever Return, (Short) SPRING, Seat Release Lever 4874 267 ADJUSTER, Manual Seat 4874 143 Passenger Passenger Passenger Passenger JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 559 40 Inches Long, (Also Serviced in 4874144) 40 Inches Long, (Also Serviced in 4874144) 40 Inches Long, (Also Serviced in 4874144) J400 6832 BOLT, Pan Head, .437-20x1.375, .437-20x1.38, Passenger & Driver Seat To Floor Pan JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION...
  • Page 560 SHIELD SIDE, Seat 4874 117 With Easy Entry With Easy Entry With Easy Entry With Easy Entry SCREW, M4.2-1.41x13 4874 111 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 561 SCREW, M4.2-1.41x13 4874 111 SPRING, Seat Lever Return 4874 266 Short Short Short Short SPRING, Seat Release Lever JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 562 28 Inches Long, (Also Serviced in 4874143) 28 Inches Long, (Also Serviced in 4874143) 28 Inches Long, (Also Serviced in 4874143) 28 Inches Long, (Also Serviced in 4874143) 4886 309AA 40 Inches Long, (Also Serviced in 4874144) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION...
  • Page 563 Contained Within Seat Track, Export Also Contained in 5012150AA & 5012151AA, Contained Within Seat Track, Export J400 6832 BOLT, Pan Head, .437-20x1.375, Passenger & Driver Seat To Floor Pan JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 564 SHIELD SIDE, Seat 4874 117 With Easy Entry With Easy Entry With Easy Entry With Easy Entry SCREW, M4.2-1.41x13 4874 111 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 565 SPRING, Seat Lever Return 4874 266 Short Short Short Short SPRING, Seat Release Lever 4874 267 Long Long JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 566 28 Inches Long, (Also Serviced in 4874143) 28 Inches Long, (Also Serviced in 4874143) 4886 309AA 40 Inches Long, (Also Serviced in 4874144) 40 Inches Long, (Also Serviced in 4874144) 40 Inches Long, (Also Serviced in 4874144) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION...
  • Page 567 Contained Within Seat Track, Export Also Serviced in 5012150AA & 5012151AA, Contained Within Seat Track, Export Also Serviced in 5012150AA & 5012151AA, Contained Within Seat Track, Export J400 6832 BOLT, Pan Head, .437-20x1.375 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 568 June 7, 2002 »...
  • Page 569 Panels, Cowl And Dash Wrangler 1999 TJ ........
  • Page 570 Rear Floor, 1997 TJ 1998 TJ, 1999 TJ SILL, Rear 5517 5788 1997 TJ 55175 788AB 1998 TJ 55175 788AC 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 571 1997 TJ, Left 1997 TJ, Left 55175 065AB 1998 TJ, 1999 TJ, Left 5517 5790 PANEL, Rear Body Closing, Lower Center Panel 5501 3668 CHECK, Front Door JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 572 PLUG PLUG, Body, Rubber #16 5517 6185 4646 855 PLUG, Floor Pan 6502 246 PLUG, Body, 4.0mm X 76.4mm, Dash Center Hole, Rubber 4.0x76.4 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 573 PLUG, Cowl Side 4646 855 PLUG, Floor Pan PLUG, Body, 4.0mm X 76.4mm (NOT SERVICED), 1999 TJ 6502 246 Dash Center Hole, Rubber 4.0x76.4, 1998 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 574 Black, Flat, SAHARA, (K50), Left 5DS7 1TJN Moss Green, SAHARA, (K50), Left 5DS7 1TW1 White, SAHARA, (K50), Left 5DS7 1TX8 Black, High Gloss, SAHARA, (K50), Left JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 575 QP95 SW1 White, SAHARA, Left QP95 WTD Sand, SAHARA, 1999 TJ 5525 4918 Black, Textured, Right 5525 4919 Black, Textured, Left JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 576 NUT, Hex, .19-32x430, Well Type Hood Bumper support, .190-32x.430 5517 6291 BUMPER, Steel Insert 6034 205 SCREW, Pan Head, .19-32x.625, Hood Bumper Support, .190-32.620 REINFORCEMENT, Hood Hinge JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 577 RETAINER, Hood Insulation, .415x.690 BRACKET, Hood Catch 5517 6428 1997 TJ 55176 428AB 1998 TJ SKID PLATE, Secondary Hood Catch, (NOT REQUIRED) RIVET, M5x11.30, (NOT REQUIRED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 578 INSULATION, Hood, (NOT REQUIRED) RETAINER, Hood Insulation, .415x.690, (NOT REQUIRED) 55176 428AC BRACKET, Hood Catch 5503 2768 SKID PLATE, Secondary Hood Catch 6500 787 RIVET, M5x11.30 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 579 REINFORCEMENT, Battery Tray 5517 4782 Right Right 5517 4783 Left Left 6101 542 SCREW, Hex Head, M8-1.25 x 20 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 580 Figure STJ-610 PART ITEM NUMBER LINE BODY DESCRIPTION PANEL, Cowl Top, Serviced in Panel Body Side, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 581 5517 4782 Right 5517 4783 Left 6100 583 BOLT AND CONED WASHER, Hex Head, M8x25x20 PANEL, Cowl Top, Serviced in Panel Body Side, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 582 Panels, Cowl And Dash Wrangler 1999 TJ Figure STJ-610 PART ITEM NUMBER LINE BODY DESCRIPTION PANEL, Cowl 55174 624AB 55174 625AB SEAL, Plenum Drain 55037 488AB 55037 489AB GRILLE, Cowl Panel 55174 636AB 55174 637AC SCREW, .164-15x1.21, (NOT SERVICED) 55037 422AA...
  • Page 583 SUPPORT, Rear View Mirror SCREW, .190-24x.500, (NOT SERVICED) 5501 3666 FOOTMAN LOOP, Hold Down PANEL, Windshield Frame 5517 4607 SCREW AND WASHER, Truss Head, .312-18x1.12 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 584 J400 7384 NUT AND WASHER, Hex 5501 9378 CAP, Hinge Cover 5517 6464 GROMMET, Wiper Motor And Bracket 5517 6421 TAPE, Anti Chip JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 585 MOLDING, Windshield Reveal 5517 5042 WEATHERSTRIP, Backlite HINGE, Liftglass 5013 722AA Right 5013 723AA Left SEAL, Header Top And Side Rail, (NOT REQUIRED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 586 J400 7384 NUT AND WASHER, Hex 5501 9378 CAP, Hinge Cover 5517 6464 GROMMET, Wiper Motor And Bracket 5517 6421 TAPE, Anti Chip JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 587 SEAL, Header Top And Side Rail, (NOT REQUIRED) 55176 430AC MOLDING, Windshield Garnish 5500 9433 GASKET, Hinge To Glass 5500 9434 BUSHING, Hinge to Glass JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 588 J400 7384 NUT AND WASHER, Hex 5501 9378 CAP, Hinge Cover 5517 6464 GROMMET, Wiper Motor And Bracket 5517 6421 TAPE, Anti Chip JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 589 1 Piece Design, After 1-16-97, Left SHIELD, Splash, Liner, Rear Wheelhouse 5517 4676 Right Right 5517 4677 Left Left RIVET, .250x.492, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 590 2.0/2.5 Thick 6503 120 SCREW AND WASHER, Button Head Torx, M8x1.25x39.50 6504 662 RETAINER, Push On, License Plate Holes 5517 6532 FOAM BLOCK, Upper B-Pillar JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 591 5DV1 3DX9 Black, Flat, SAHARA, Left 5DV1 3TX8 Black, High Gloss, SAHARA, Left 6504 397 NUT, M8-1.25 6501 648 SCREW, Hex Flange Head, M8x1.25x25.00, Side Step JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 592 5507 5483 2.0/2.5 Thick 6503 120 SCREW AND WASHER, Button Head Torx, M8x1.25x39.50 6504 662 RETAINER, Push On, License Plate Holes FOAM BLOCK, Upper B-Pillar, (NOT REQUIRED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 593 Panels, Body Side Wrangler 1999 TJ Figure STJ-810 PART ITEM NUMBER LINE BODY DESCRIPTION PANEL, Body Side 4874 196AB Right 4874 197AB Left PANEL, Rear Corner 5517 5664 Right 5517 5665 Left 5517 5024 REINFORCEMENT, Side Panel SEAL, Mucket 55176 524AB...
  • Page 594 Panels, Body Side Wrangler 1999 TJ Figure STJ-810 PART ITEM NUMBER LINE BODY DESCRIPTION STEP PAD, Side Step 5517 5158 Right 5517 5159 Left RETAINER, Belt Rail 55175 754AB Right 55175 755AB Left 4520 288 STRIKER, Door Latch, Door Latch...
  • Page 595 4874 281 BOW, Folding Top, Number 1, Soft Top, #1,#2, w/Pivot, Includes Front Header 5517 6206 BUMPER, Rubber, # 2 Bow Rest BRACKET, Soft Top Bow 1 & 3 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 596 55176 739AA After 1-6-97, Left RETAINER, Soft Top Rail 55176 736AA After 1/6/97 5517 6232 Up to 1/6/97 TOOL, Wrench, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 597 5517 6287 LATCH AND BASE, Folding Top BOW, Folding Top, Number 3 55176 442AB With Pivot, After 12-3-96, 1998 TJ 1999 TJ SNAP KIT, Soft Top JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 598 5517 6064 KNUCKLE, Rear KNUCKLE, Rear 5517 5813 1998 TJ 1999 TJ SCREW AND WASHER, .164-18x.625, (NOT SERVICED) CLIP, Tailgate Opening JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 599 RETAINER, Soft Top Rail 55176 736AA 1998 TJ 55176 736AB 1999 TJ TOOL, Wrench (NOT SERVICED), 1998 TJ # 55177 245AA Torx, 1999 TJ JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 600 5517 6465 MOLDING, Door Window Opening 55176 746AA RETAINER, Folding Top Deck Closure, Dual Top Nut Plate 5517 6466 BUMPER, Upper Slam, Hardtop to Sport Bar TOOL, Wrench, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 601 COVER, Wiring Protector MOLDING, Door Window Opening, (NOT REQUIRED) 55176 746AA RETAINER, Folding Top Deck Closure, Dual Top Nut Plate 5517 6466 BUMPER, Upper Slam TOOL, Wrench, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 602 COVER, Wiring Protector MOLDING, Door Window Opening, (NOT REQUIRED) 55176 746AB RETAINER, Folding Top Deck Closure 5517 6466 BUMPER, Upper Slam # 55177 245AA TOOL, Wrench, Torx JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 603 5502 5280 WATERSHIELD, Tailgate Latch RETAINER, Soft Top Rail 5517 6232 Up to 1-6-97 55176 736AA After 1-6-97 REINFORCEMENT, Tailgate Hinge JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 604 PART ITEM NUMBER LINE BODY DESCRIPTION 5517 5668 SCREW AND WASHER, Hex Head, .312-18x1.12 J400 4455 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech DGG, DGD = 32RH 3 Spd.
  • Page 605 5502 5280 WATERSHIELD, Tailgate Latch 55176 736AA RETAINER, Soft Top Rail 5517 5668 REINFORCEMENT, Tailgate Hinge J400 4455 SCREW AND WASHER, Hex Head, .312-18x1.12 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB EPE, EP0 = 2.5L Power Tech...
  • Page 606 Tailgate Wrangler 1999 TJ Figure STJ-1310 PART ITEM NUMBER LINE BODY DESCRIPTION 55176 340AC TAILGATE 55008 127AB ROD, Tailgate Handle to Latch SLEEVE, Anti-Rattle, Handle to Latch Rod, (NOT SERVICED) J400 4532 CLIP, Rod End, Attach Lock Cylinder Rod 5517 6547...
  • Page 607 Saddle, 1998 TJ 5521 6140 THUMBSCREW, M6x1-17 6101 719 SCREW AND WASHER, Tapping, M6-1.0x20.0 6503 245 NUT/RIVET, Cooler To Closure Panel, M6x1.00 PLUG, (NOT SERVICED) JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 608 Spice, Without Speakers, 1998 TJ 5FV0 8LAZ Agate, With Speakers 5FV0 8RT6 Spice, With Speakers, 1997 TJ, 1998 TJ 5GA17 LAZAA 1 Agate, Without Speakers, 1998 TJ, 1999 TJ, Export JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...
  • Page 609 Saddle, 1998 TJ, Export 5FC9 8RK5 Camel, 1999 TJ, Export NUT, Snap In, .164-18 6035 912 Shield to Sport Bar, 1997 TJ 1998 TJ, 1999 TJ 6504 665 JEEP WRANGLER (TJ) —————————————————————————————————————————————————————————————— SERIES LINE BODY ENGINE TRANSMISSION L=Low Line J = Wrangler 4WD 77 = 93.4 WB...

  • Page 610: Lubrication And Maintenance

    LUBRICATION AND MAINTENANCE 0 - 1 LUBRICATION AND MAINTENANCE CONTENTS page page GENERAL INFORMATION ....1 MAINTENANCE SCHEDULES ....3 JUMP STARTING, HOISTING AND TOWING .
  • Page 611 0 - 2 LUBRICATION AND MAINTENANCE GENERAL INFORMATION (Continued) API QUALITY CLASSIFICATION FLUID CAPACITIES This symbol (Fig. 2) on the front of an oil container FUEL TANK means that the oil has been certified by the American Petroleum Institute (API) to meet all the lubrication requirements specified by Chrysler Corpo- Standard .

  • Page 612: Maintenance Schedules

    LUBRICATION AND MAINTENANCE 0 - 3 MAINTENANCE SCHEDULES INDEX page GENERAL INFORMATION MAINTENANCE SCHEDULES ....3 • Rotate the tires at each oil change interval GENERAL INFORMATION shown on Schedule “A”...
  • Page 613 0 - 4 LUBRICATION AND MAINTENANCE GENERAL INFORMATION (Continued) • Flush and replace engine coolant if it has been 30,000 Miles (48 000 km) or at 24 months • Change engine oil. 30,000 miles (48 000 km) or 24 months since last •...
  • Page 614 LUBRICATION AND MAINTENANCE 0 - 5 GENERAL INFORMATION (Continued) • Lubricate steering linkage. • Lubricate steering linkage. • Drain and refill automatic transmission fluid. • Drain and refill automatic transmission fluid. • Drain and refill transfer case fluid. • Drain and refill front and rear axles.‡ •...
  • Page 615 0 - 6 LUBRICATION AND MAINTENANCE GENERAL INFORMATION (Continued) • Lubricate steering linkage. • Lubricate steering linkage. • Drain and refill automatic transmission fluid. • Drain and refill automatic transmission fluid. • Drain and refill front and rear axles.‡ • Drain and refill front and rear axles.‡ •...
  • Page 616 LUBRICATION AND MAINTENANCE 0 - 7 GENERAL INFORMATION (Continued) • Flush and replace engine coolant if it has been 96,000 Miles (154 000 km) • Change engine oil. 30,000 miles (48 000 km) since last change. • Lubricate steering linkage. •...
  • Page 617 0 - 8 LUBRICATION AND MAINTENANCE JUMP STARTING, HOISTING AND TOWING INDEX page page SERVICE PROCEDURES RECREATIONAL TOWING ....10 EMERGENCY TOW HOOKS ....10 TOWING RECOMMENDATIONS .
  • Page 618 LUBRICATION AND MAINTENANCE 0 - 9 SERVICE PROCEDURES (Continued) DISCONNECT CABLE CLAMPS AS FOLLOWS: SAFETY PRECAUTIONS • Disconnect BLACK cable clamp from engine • Secure loose and protruding parts. • Always use a safety chain system that is inde- ground on disabled vehicle. •...

  • Page 619: Frame Rail

    FLOOR JACK When properly positioned, a floor jack can be used to lift a Jeep vehicle (Fig. 6). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails.

  • Page 620: Frame Rail

    LUBRICATION AND MAINTENANCE 0 - 11 SERVICE PROCEDURES (Continued) • An axle tube. • A ramp-type, drive-on hoist. • A body side sill. • A steering linkage component. NOTE: When a frame-contact type hoist is used, • A drive shaft. verify that the lifting pads are positioned properly.

  • Page 622: Exhaust System

    EXHAUST SYSTEM 11 - 1 EXHAUST SYSTEM CONTENTS page page GENERAL INFORMATION REMOVAL AND INSTALLATION CATALYTIC CONVERTER ....1 CATALYTIC CONVERTER/EXHAUST PIPE ..3 EXHAUST HEAT SHIELDS .
  • Page 623 11 - 2 EXHAUST SYSTEM GENERAL INFORMATION (Continued) Fig. 1 Exhaust System—2.5L Engine Fig. 2 Exhaust System—4.0L Engine...
  • Page 624 EXHAUST SYSTEM 11 - 3 DIAGNOSIS AND TESTING EXHAUST SYSTEM EXHAUST SYSTEM DIAGNOSIS CHART CONDITION POSSIBLE CAUSE CORRECTION EXCESSIVE EXHAUST NOISE OR 1. Leaks at pipe joints. 1. Tighten clamps/bolts at leaking LEAKING EXHAUST GASES joints. 2. Rusted or blown out muffler. 2.
  • Page 625 11 - 4 EXHAUST SYSTEM REMOVAL AND INSTALLATION (Continued) (7) Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed. MUFFLER AND TAILPIPE ASSEMBLY WARNING: THE NORMAL OPERATING TEMPERA- TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
  • Page 626 EXHAUST SYSTEM 11 - 5 REMOVAL AND INSTALLATION (Continued) Fig. 6 Muffler and Tailpipe Assembly (3) Remove the tailpipe hangers from the insula- SPECIFICATIONS tors (Fig. 6). (4) Heat the catalytic converter-to-muffler connec- TORQUE SPECIFICATIONS tion with an oxyacetylene torch until the metal becomes cherry red.
  • Page 628 Tighten the bolts to 108 N·m (80 ft. lbs.) torque. FRONT TOW HOOK Some Jeep vehicles are equipped with front emer- FRONT BUMPER EXTENSION gency tow hooks. The tow hooks should be used for EMERGENCY purposes only.

  • Page 629: Frame Rail

    13 - 2 FRAME AND BUMPERS REMOVAL AND INSTALLATION (Continued) FRONT BUMPER REMOVAL (1) If equipped, disconnect the fog lamp harness connector. (2) Remove the screws that attach the bumper to the frame rail (Fig. 3). (3) If equipped, remove the tow hook. (4) Separate the bumper from the vehicle.
  • Page 630 N·m (35 ft. lbs.) torque. GENERAL INFORMATION The frame is constructed of mild-strength rectan- The Jeep TJ frame is the structural center of the gular tubing and crossmembers. The crossmembers vehicle. In addition to supporting the body and pay- join the siderails and retain them in alignment in load, the frame provides a station for the engine.

  • Page 631: Frame Rail

    13 - 4 FRAME AND BUMPERS FRAME REPAIRS SERVICE PROCEDURES DRILLING HOLES FRAME SERVICE Do not drill holes in the top and bottom of frame rail, metal fatigue can result causing frame failure. SAFETY PRECAUTIONS AND WARNINGS Holes drilled in the side of the frame rail must be at least 38 mm (1.5 in.) from the top and bottom WARNING: USE EYE PROTECTION WHEN GRIND- flanges.
  • Page 632 FRAME AND BUMPERS 13 - 5 SERVICE PROCEDURES (Continued) Fig. 4 Transmission Mount—Automatic Transmission Fig. 3 Energy Management Holes FRAME FASTENERS Bolts and nuts and can be used to repair frames or to install a reinforcement section on the frame. Conical-type washers are preferred over the split- ring type lock washers.
  • Page 633 13 - 6 FRAME AND BUMPERS REMOVAL AND INSTALLATION (Continued) (3) Install the nuts attaching the transmission mount to the skid plate. Tighten the nuts to 28 N·m (21 ft. lbs.) torque. (4) Remove the support under the transmission. (5) Remove the support from under the vehicle and lower the vehicle.
  • Page 634 FRAME AND BUMPERS 13 - 7 SPECIFICATIONS FRAME DIMENSIONS FRAME SIDE VIEW...
  • Page 635 13 - 8 FRAME AND BUMPERS SPECIFICATIONS (Continued) FRAME TOP VIEW...
  • Page 636 FRAME AND BUMPERS 13 - 9 SPECIFICATIONS (Continued) TORQUE SPECIFICATIONS DESCRIPTION TORQUE Front Bumper Screw ..104 N·m (77 ft. lbs.) Front Tow Hook Screw ..108 N·m (80 ft. lbs.) Fuel Tank Skid Plate Nuts .
  • Page 638 FRAME AND BUMPERS 13 - 1 FRAME AND BUMPERS CONTENTS page BUMPERS ....... 1 BUMPERS INDEX page...
  • Page 639 13 - 2 FRAME AND BUMPERS REMOVAL AND INSTALLATION (Continued) FRONT LICENSE PLATE BRACKET REAR LICENSE PLATE BRACKET REMOVAL REMOVAL (1) Remove the front license plate bracket attach- (1) Remove the rear license plate bracket attach- ing bolts and bracket (Fig. 3). ing screws (Fig.
  • Page 640 FUEL SYSTEM 14 - 1 FUEL SYSTEM CONTENTS page page FUEL DELIVERY SYSTEM ....1 FUEL INJECTION SYSTEM ....23 FUEL DELIVERY SYSTEM INDEX page...

  • Page 641: Fuel Delivery System

    14 - 2 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) vehicle. Chrysler recommends the use of gasoline Illumination of either light while operating on high that meet the AAMA specifications if they are avail- sulfur gasoline does not necessarily mean your emis- able.
  • Page 642 FUEL SYSTEM 14 - 3 DESCRIPTION AND OPERATION (Continued) gauge sending unit (fuel level sensor) and a separate fuel filter located at bottom of pump module • fuel tubes/lines/hoses • quick-connect fittings • fuel injector rail • fuel injectors • fuel tank •...

  • Page 643: Fuel Filter/Fuel Pressure Regulator

    14 - 4 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition.

  • Page 644: Fuel Rail/Fuel Damper-2.5L Engine

    FUEL SYSTEM 14 - 5 DESCRIPTION AND OPERATION (Continued) ROLLOVER VALVE(S) FUEL RAIL/FUEL DAMPER—2.5L ENGINE Refer to Group 25, Emission Control System for The fuel rail supplies the necessary fuel to each information. individual fuel injector and is mounted to the intake manifold (Fig.

  • Page 645: Fuel Tank Filler Tube Cap

    14 - 6 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) DIAGNOSIS AND TESTING FUEL PUMP PRESSURE TEST—ALL ENGINES WITH PRESSURE TEST PORT Use this test in conjunction with the Fuel Pump Capacity Test, Fuel Pressure Leak Down Test and Fuel Pump Amperage Test found elsewhere in this group.
  • Page 646 FUEL SYSTEM 14 - 7 DIAGNOSIS AND TESTING (Continued) (2) Start and warm engine and note pressure to Fuel Filter/Fuel Pressure Regulator Removal/In- gauge reading. Fuel pressure should be 339 kPa stallation for additional information. kPa (49.2 psi 5 psi) at idle. (c) If both fuel pressure and capacity are low, (3) If engine runs, but pressure is below 44.2 psi, replace fuel pump module assembly.
  • Page 647 14 - 8 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) check valves in either the electric fuel pump or filter/ regulator may be leaking. Note: A quick loss of pressure usually indicates a defective check valve in the filter/regulator. A slow loss of pressure usually indicates a defective check valve in the electric fuel pump.
  • Page 648 FUEL SYSTEM 14 - 9 DIAGNOSIS AND TESTING (Continued) (8) Press ENTER three times. (9) Using up/down arrow keys, highlight RANGE on DRB screen (screen will default to 2 amp scale). (10) Press ENTER to change 2 amp scale to 10 amp scale.

  • Page 649: Fuel Gauge Sending Unit

    14 - 10 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) (18) Disconnect test leads from relay cavities Leak Detection Pump (LDP). The vehicle may be immediately after testing. equipped with flap installed into fuel filler tube even though vehicle is not equipped with LDP FUEL GAUGE SENDING UNIT and EVAP monitor system.

  • Page 650: Quick-Connect Fittings

    FUEL SYSTEM 14 - 11 SERVICE PROCEDURES (Continued) Inspect all hose connections such as clamps, cou- plings and fittings to make sure they are secure and leaks are not present. The component should be replaced immediately if there is any evidence of deg- radation that could result in failure.
  • Page 651 14 - 12 FUEL SYSTEM SERVICE PROCEDURES (Continued) (6) Raise pull tab until it separates from quick- connect fitting (Fig. 17). Discard old pull tab. Fig. 18 Typical Two-Tab Type Quick-Connect Fitting WARNING: THE FUEL SYSTEM IS UNDER A CON- Fig.
  • Page 652 FUEL SYSTEM 14 - 13 SERVICE PROCEDURES (Continued) (7) Insert quick-connect fitting to component being (3) Clean fitting of any foreign material before dis- serviced and into plastic retainer. When a connection assembly. is made, a click will be heard. (4) To release fuel system component from quick- (8) Verify a locked condition by firmly pulling on connect fitting, firmly push fitting towards compo-...

  • Page 653: Removal And Installation

    14 - 14 FUEL SYSTEM SERVICE PROCEDURES (Continued) properly installed to fuel rail. Recheck fuel line connection. (12) Verify a locked condition by firmly pulling on fuel line and fitting (15-30 lbs.). (13) Connect negative battery cable to battery. (14) Start engine and check for leaks. REMOVAL AND INSTALLATION FUEL FILTER/FUEL PRESSURE REGULATOR The combination Fuel Filter/Fuel Pressure Regula-...
  • Page 654 FUEL SYSTEM 14 - 15 REMOVAL AND INSTALLATION (Continued) (6) The molded arrow (Fig. 22) on top of fuel pump module should be pointed towards front of vehicle (12 o’clock position). (7) Rotate filter/regulator until fuel supply tube (fitting) is pointed to 10 o’clock position. (8) Install new retainer clamp (clamp snaps over top of filter/regulator and locks to flanges on pump module).

  • Page 655: Fuel Gauge Sending Unit

    14 - 16 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 26 Locknut Removal/Installation—Typical INSTALLATION Fig. 27 Fuel Pump Inlet Filter CAUTION: Whenever the fuel pump module is ser- FUEL GAUGE SENDING UNIT viced, the module gasket must be replaced. The fuel gauge sending unit (fuel level sensor) and (1) Using a new gasket, position fuel pump module float assembly is located on the side of fuel pump into opening in fuel tank.

  • Page 656: Fuel Injector Rail-2.5L Engine

    FUEL SYSTEM 14 - 17 REMOVAL AND INSTALLATION (Continued) Fig. 30 Fuel Rail Mounting—2.5L Engine Fig. 29 Fuel Gauge Sending Unit Release Tab (9) Disconnect automatic transmission cable at (2) Connect electrical connector to terminals. throttle body (if equipped). (3) Install fuel pump module. Refer to Fuel Pump (10) Remove cable routing bracket (Fig.

  • Page 657: Fuel Injector Rail-4.0L Engine

    14 - 18 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (9) Install cable routing bracket to intake mani- (6) Disconnect fuel supply line latch clip and fuel fold. line at fuel rail. Refer to Quick-Connect Fittings in (10) Connect throttle cable at throttle body. this group for procedures.

  • Page 658: Fuel Tank

    FUEL SYSTEM 14 - 19 REMOVAL AND INSTALLATION (Continued) FUEL INJECTORS FUEL TANK REMOVAL WARNING: THE FUEL SYSTEM IS UNDER CON- STANT FUEL PRESSURE EVEN WITH THE ENGINE (1) Remove fuel rail. Refer to Fuel Injector Rail OFF. THIS PRESSURE MUST RELEASED Removal in this section.
  • Page 659 14 - 20 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (12) Remove four skid plate-to-body nuts at rear of tank (Fig. 36). Do not loosen tank strap nuts (Fig. 36). (13) Lower the tank assembly. (14) If fuel pump module is to be removed, refer to Fuel Pump Module Removal/Installation.

  • Page 660: Fuel Tank Filler Tube Cap

    FUEL SYSTEM 14 - 21 REMOVAL AND INSTALLATION (Continued) Fig. 37 Fuel Tank Mounting Nuts—Front FUEL TANK FILLER TUBE CAP If replacement of the fuel tank filler tube cap is Fig. 38 Accelerator Pedal Mounting necessary, it must be replaced with an identical cap INSTALLATION to be sure of correct system operation.

  • Page 661: Specifications

    14 - 22 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (2) Snap cable into clip guides on engine cylinder head (valve) cover. (3) Push other end of cable through opening in dash panel until retaining tabs lock into panel. (4) From inside drivers compartment, slide throttle cable core wire into opening in top of accelerator pedal arm.
  • Page 662 FUEL SYSTEM 14 - 23 FUEL INJECTION SYSTEM INDEX page page GENERAL INFORMATION MANIFOLD ABSOLUTE PRESSURE (MAP) INTRODUCTION ......24 SENSOR—PCM INPUT .
  • Page 663 14 - 24 FUEL SYSTEM POWER STEERING PRESSURE SWITCH—2.5L VEHICLE SPEED SENSOR ....49 ENGINE ......46 SPECIFICATIONS POWERTRAIN CONTROL MODULE (PCM) .
  • Page 664 FUEL SYSTEM 14 - 25 GENERAL INFORMATION (Continued) ENGINE START-UP MODE sure A/C switches. Refer to Group 24, Heating and Air Conditioning for additional information. This is an Open Loop mode. The following actions • When engine has reached operating tempera- occur when the starter motor is engaged.
  • Page 665 14 - 26 FUEL SYSTEM GENERAL INFORMATION (Continued) • Air conditioning select signal (if equipped) If the vehicle is under hard deceleration with the • Air conditioning request signal (if equipped) proper rpm and closed throttle conditions, the PCM • Battery voltage will ignore the oxygen sensor input signal.
  • Page 666 FUEL SYSTEM 14 - 27 DESCRIPTION AND OPERATION (Continued) • Vehicle speed sensor The PCM can adapt its programming to meet chang- ing operating conditions. NOTE: Powertrain Control Module (PCM) Outputs: The PCM receives input signals from various switches and sensors. Based on these inputs, the •...
  • Page 667 FIVE VOLT SENSOR SUPPLY—PRIMARY and fuel injectors to the 12 volt + power supply. Jeep Supplies the required 5 volt power source to the models of previous years had used the ASD relay to...
  • Page 668 FUEL SYSTEM 14 - 29 DESCRIPTION AND OPERATION (Continued) Fig. 3 Camshaft Position Sensor—Typical The sensor is bolted to the transmission bellhous- ing. Fig. 4 Engine Coolant Temperature Sensor—Typical Refer to Group 8D, Ignition System for more crankshaft position sensor information. present (caused by a lean air/fuel mixture), the sen- The engine will not operate if the PCM does not sors produces a low voltage.
  • Page 669 14 - 30 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) tor (MIL) (or Check Engine) lamp. For more informa- tion, refer to Group 25, Emission Control Systems. The downstream sensor input is also used to adjust the upstream O2S goal voltage. This allows a better control of the exhaust gases as the catalytic conver- tor ages.
  • Page 670 FUEL SYSTEM 14 - 31 DESCRIPTION AND OPERATION (Continued) POWER STEERING PRESSURE SWITCH—PCM INPUT A pressure sensing switch is included in the power steering system (mounted on the high-pressure line). This switch will be used only on vehicles equipped with a 2.5L engine and power steering. The switch (Fig.
  • Page 671 14 - 32 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) through resistive multiplexing. The input circuit voltage is measured by the PCM to determine which switch function has been selected. A speed control indicator lamp, located on the instrument panel cluster is energized by the PCM via the CCD Bus.
  • Page 672 FUEL SYSTEM 14 - 33 DESCRIPTION AND OPERATION (Continued) Fig. 11 Power Distribution Center (PDC) clutch. This is based on changes in engine operating conditions. The PCM will also de-energize the relay if Fig. 12 Data Link Connector Location coolant temperature exceeds 125°C (257°F). DUTY CYCLE EVAP PURGE SOLENOID AUTO SHUTDOWN (ASD) RELAY—PCM VALVE-PCM OUTPUT...
  • Page 673 14 - 34 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) engine idle speed by moving the IAC motor pintle in and out of the air control passage. The IAC motor is positioned when the ignition key is turned to the On position.
  • Page 674 FUEL SYSTEM 14 - 35 DESCRIPTION AND OPERATION (Continued) Fig. 14 Throttle Body (4.0L Engine Shown) The Throttle Position Sensor (TPS), IAC motor and Manifold Absolute Pressure sensor (MAP) Fig. 15 Powertrain Control Module (PCM) attached to the throttle body. The accelerator pedal cable, speed control cable (when equipped) and auto- matic transmission control cable (when equipped) are connected to the throttle arm.

  • Page 675: 2.5L Engine

    14 - 36 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) (13) Inspect air cleaner inlet and air cleaner ele- ment for dirt or restrictions. (14) Inspect radiator grille area, radiator fins and air conditioning condenser for restrictions. (15) Verify intake manifold air temperature sensor wire connector is firmly connected to harness connec- tor (Fig.
  • Page 676 FUEL SYSTEM 14 - 37 DIAGNOSIS AND TESTING (Continued) Fig. 21 Rubber L-Shaped Fitting—MAP Sensor-to- Fig. 23 Upstream Oxygen Sensor Throttle Body with injector number (INJ 1, INJ 2 etc.) of its corre- sponding fuel injector and cylinder number. (18) Verify harness connectors are firmly con- nected to Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) (Fig.
  • Page 677 14 - 38 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) Fig. 27 ASD and Fuel Pump Relay Terminals OPERATION • Terminal number 30 is connected to battery volt- age. For both the ASD and fuel pump relays, termi- nal 30 is connected to battery voltage at all times. •...
  • Page 678 FUEL SYSTEM 14 - 39 DIAGNOSIS AND TESTING (Continued) power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CON- TACT TERMINALS 85 OR 86 DURING THIS TEST. (7) Attach the other end of the jumper wire to relay terminal 86.
  • Page 679 14 - 40 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) priate Powertrain Diagnostics Procedures manual. To ENGINE COOLANT TEMPERATURE SENSOR test the O2S sensors only, refer to the following: To perform a complete test of the engine coolant The upstream O2S sensor is located on the exhaust temperature sensor and its circuitry, refer to DRB downpipe (Fig.

  • Page 680: 4.0L Engine

    FUEL SYSTEM 14 - 41 DIAGNOSIS AND TESTING (Continued) SENSOR RESISTANCE (OHMS)—COOLANT TEMPERATURE SENSOR/INTAKE AIR TEMPERATURE SENSOR TEMPERATURE RESISTANCE (OHMS) °CEL. °FAHR. MIN. MAX. 291,490 381,710 85,850 108,390 49,250 61,430 29,330 35,990 17,990 21,810 11,370 13,610 9,120 10,880 7,370 8,750 4,900 5,750 Fig.
  • Page 681 14 - 42 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) (2) Connect a pair of jumper wires to switch termi- voltage must be less than 4.49 volts. The output volt- nals. Route and secure jumper wires away from fan age should increase gradually as the throttle plate is blades and fan belt.
  • Page 682 FUEL SYSTEM 14 - 43 DIAGNOSIS AND TESTING (Continued) (10) Remove orifice tool and connect CCV tube to engine. (11) Install air duct to throttle body. REMOVAL AND INSTALLATION AUTOMATIC SHUTDOWN (ASD) RELAY The ASD relay is located in the Power Distribution Center (PDC) (Fig.
  • Page 683 14 - 44 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Install relay to PDC. (2) Install cover to PDC. THROTTLE BODY A (factory adjusted) set screw is used to mechani- cally limit the position of the throttle body throttle plate.
  • Page 684 FUEL SYSTEM 14 - 45 REMOVAL AND INSTALLATION (Continued) throttle shaft on the other side of the socket tangs). (2) Install and tighten two mounting bolts (screws) The TPS will be under slight tension when rotated. to 7 N·m (60 in. lbs.) torque. (3) Install electrical connector.
  • Page 685 14 - 46 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) POWERTRAIN CONTROL MODULE (PCM) POWER STEERING PRESSURE SWITCH—2.5L The PCM is located in the engine compartment ENGINE (Fig. 47). This switch is not used with 4.0L six-cylinder engines. The power steering pressure switch is installed in the power steering high-pressure hose (Fig.
  • Page 686 FUEL SYSTEM 14 - 47 REMOVAL AND INSTALLATION (Continued) (3) Remove O2S sensor. Snap-On oxygen sensor wrench number YA 8875 (or equivalent) may be used for removal and installation. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor.
  • Page 687 14 - 48 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION INTAKE MANIFOLD AIR TEMPERATURE (1) Install air cleaner element into housing. SENSOR (2) Install housing cover to housing. Be sure cover The intake manifold air temperature (IAT) sensor is properly seated to air cleaner housing. is installed into intake manifold plenum near throttle (3) Connect air tube at cover.
  • Page 688 FUEL SYSTEM 14 - 49 REMOVAL AND INSTALLATION (Continued) VEHICLE SPEED SENSOR REMOVAL (1) Raise and support vehicle. The vehicle speed sensor is located on the speed- (2) Disconnect electrical connector from sensor. ometer pinion gear adapter. The pinion gear adapter (3) Remove sensor mounting bolt (Fig.
  • Page 689 14 - 50 FUEL SYSTEM SPECIAL TOOLS FUEL SYSTEM O2S (Oxygen Sensor) Remover/Installer—C-4907 Spanner Wrench—6856 Adapters, Fuel Pressure Test—6539 and/or 6631 Test Kit, Fuel Pressure—5069 Fitting, Air Metering—6714 Test Kit, Fuel Pressure—C-4799-B Fuel Line Removal Tool—6782...

  • Page 690: Light Spark Knock At Low Engine Speeds Is Not

    FUEL SYSTEM 14 - 1 FUEL SYSTEM CONTENTS page GENERAL INFORMATION FUEL REQUIREMENTS—LEADED FUEL VEHICLES ......1 GENERAL INFORMATION Engine damage resulting from operating with a heavy spark knock may not be covered by the new...

  • Page 692: Power Steering

    STEERING 19 - 1 STEERING CONTENTS page page POWER STEERING ......1 STEERING COLUMN ..... . 25 POWER STEERING GEAR .
  • Page 693 19 - 2 STEERING DIAGNOSIS AND TESTING POWER STEERING SYSTEM DIAGNOSIS CHARTS STEERING NOISE There is some noise in all power steering systems. One of the most common is a hissing sound evident at a standstill parking. Or when the steering wheel is at the end of it’s travel. Hiss is a high frequency noise similar to that of a water tap being closed slowly.
  • Page 694 STEERING 19 - 3 DIAGNOSIS AND TESTING (Continued) BINDING AND STICKING CONDITION POSSIBLE CAUSE CORRECTION 1. Low fluid level. 1. Fill to proper level. DIFFICULT TO TURN WHEEL STICKS OR BINDS 2. Tire pressure. 2. Adjust tire pressure. 3. Steering component. 3.
  • Page 695 19 - 4 STEERING DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION VEHICLE PULLS OR LEADS TO 1. Tire Pressure. 1. Adjust tire pressure. ONE SIDE 2. Radial tire lead. 2. Cross front tires. 3. Brakes dragging. 3. Repair as necessary. 4.
  • Page 696 STEERING 19 - 5 DIAGNOSIS AND TESTING (Continued) CAUTION: Do not force the pump to operate against the stops for more than 2 to 4 seconds at a time because, pump damage will result. PUMP SPECIFICATIONS ENGINE RELIEF PRESSURE FLOW RATE (GPM) 2.5L 9653 kPa (1400 psi) 1500 RPM 2.4 - 2.8 GPM...

  • Page 697: Power Steering Pump

    19 - 6 STEERING POWER STEERING PUMP INDEX page page DESCRIPTION AND OPERATION PUMP REMOTE RESERVOIR – 2.5L ..7 POWER STEERING PUMP ....6 DISASSEMBLY AND ASSEMBLY DIAGNOSIS AND TESTING FLOW CONTROL VALVE .
  • Page 698 STEERING 19 - 7 (7) Lower the vehicle, start the engine and turn DIAGNOSIS AND TESTING the steering wheel slowly from lock to lock. (8) Stop the engine and check the fluid level and PUMP LEAKAGE DIAGNOSIS refill as required. (9) If the fluid is extremely foamy or milky look- ing, allow the vehicle to stand a few minutes and repeat the procedure.
  • Page 699 19 - 8 STEERING REMOVAL AND INSTALLATION (Continued) Fig. 2 Pump Mounting DISASSEMBLY AND ASSEMBLY PUMP PULLEY DISASSEMBLY (1) Remove pump assembly. (2) Remove pulley from pump with Puller C-4333 (Fig. 4). Fig. 3 Pump Reservoir – 2.5L (4) Fill reservoir to proper level, refer to Power Steering Pump Initial Operation.
  • Page 700 STEERING 19 - 9 DISASSEMBLY AND ASSEMBLY (Continued) ASSEMBLY (1) Replace pulley if bent, cracked, or loose. (2) Install pulley on pump with Installer C-4063-B (Fig. 5) flush with the end of the shaft. Ensure the tool and pulley remain aligned with the pump shaft. Fig.
  • Page 701 19 - 10 STEERING DISASSEMBLY AND ASSEMBLY (Continued) (2) Install O-ring seal onto fitting. (3) Install flow control valve in pump housing and tighten to 75 N·m (55 ft. lbs.). (4) Install pressure hose to valve. SPECIFICATIONS TORQUE CHART DESCRIPTION TORQUE Adapters, Power Steering Flow/Pressure Tester Power Steering Pump...

  • Page 702: Power Steering Gear

    STEERING 19 - 11 POWER STEERING GEAR INDEX page page DESCRIPTION AND OPERATION RACK PISTON AND WORM SHAFT ..17 POWER STEERING GEAR ....11 SPOOL VALVE .
  • Page 703 19 - 12 STEERING DESCRIPTION AND OPERATION (Continued) Fig. 1 Recirculating Ball Type Gear...

  • Page 704: Frame Rail

    STEERING 19 - 13 DIAGNOSIS AND TESTING POWER STEERING GEAR LEAKAGE DIAGNOSIS Fig. 2 Steering Gear Mounting (5) Install power steering hoses/tubes to power steering pump. (6) Fill power steering system to proper level, refer to Steering Pump Initial Operation. DISASSEMBLY AND ASSEMBLY HOUSING END PLUG DISASSEMBLY...
  • Page 705 19 - 14 STEERING DISASSEMBLY AND ASSEMBLY (Continued) (2) Slowly rotate stub shaft with 12 point socket PITMAN SHAFT/SEALS/BEARING COUNTER-CLOCKWISE to force the end plug out from housing. DISASSEMBLY (1) Clean exposed end of pitman shaft and housing CAUTION: Do not turn stub shaft any further than with a wire brush.
  • Page 706 STEERING 19 - 15 DISASSEMBLY AND ASSEMBLY (Continued) (9) Install preload adjuster nut. Do not tighten nut until after Over-Center Rotation Torque adjustment has been made. (10) Install gasket to side cover and bend tabs around edges of side cover (Fig. 6). (11) Install pitman shaft assembly and side cover to housing.
  • Page 707 19 - 16 STEERING DISASSEMBLY AND ASSEMBLY (Continued) Fig. 10 Thrust Support Assembly Fig. 12 Stub Shaft Fig. 11 Valve Assembly With Stub Shaft ASSEMBLY NOTE: Clean and dry all components, then lubri- cate with power steering fluid. Fig. 13 Spool Valve (1) Install spool valve spool O-ring.
  • Page 708 STEERING 19 - 17 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 16 Stub Shaft Cap O-Ring Fig. 14 Valve Seals Fig. 17 Rack Piston End Plug (6) Turn the stub shaft with a 12 point socket COUNTERCLOCKWISE, this will force the rack pis- ton onto the tool and hold the rack piston balls in place.
  • Page 709 19 - 18 STEERING DISASSEMBLY AND ASSEMBLY (Continued) Fig. 18 Rack Piston with Arbor Fig. 20 Rack Piston Teflon Ring and O-Ring Fig. 19 Rack Piston (14) Remove the worm shaft from the housing (Fig. 21). ASSEMBLY Fig. 21 Worm Shaft (4) Lubricate and install rack piston balls through NOTE: Clean and dry all components and lubricate return guide hole while turning worm shaft COUN-...
  • Page 710 STEERING 19 - 19 DISASSEMBLY AND ASSEMBLY (Continued) ADJUSTMENTS STEERING GEAR CAUTION: Steering gear must be adjusted in the proper order. If adjustments are not performed in order, gear damage and improper steering response may result. NOTE: Adjusting the steering gear in the vehicle is not recommended.
  • Page 711 19 - 20 STEERING ADJUSTMENTS (Continued) Fig. 25 Alignment Marking On Housing Fig. 27 Aligning To The Second Mark Fig. 26 Second Marking On Housing OVER-CENTER Fig. 28 Steering Gear Centered NOTE: Before performing this procedure, the worm bearing preload adjustment must be performed. NOTE: The stub shaft must rotate smoothly without sticking or binding.
  • Page 712 STEERING 19 - 21 ADJUSTMENTS (Continued) (6) If an adjustment to the Over-Center Rotating TORQUE CHART Torque is necessary, first loosen the adjuster lock nut. Then turn the pitman shaft adjuster screw back DESCRIPTION TORQUE (COUNTERCLOCKWISE) until fully extended, then Power Steering Gear turn back in (CLOCKWISE) one full turn.

  • Page 713: Steering Linkage

    19 - 22 STEERING STEERING LINKAGE INDEX page page DESCRIPTION AND OPERATION PITMAN ARM ......23 STEERING LINKAGE .
  • Page 714 STEERING 19 - 23 REMOVAL AND INSTALLATION (Continued) (2) Install the washer and nut on the shaft and tighten the nut to 251 N·m (185 ft. lbs.). (3) Install drag link ball stud to pitman arm. Install nut and tighten to 81 N·m (60 ft. lbs.). Install a new cotter pin.
  • Page 715 19 - 24 STEERING SPECIFICATIONS SPECIAL TOOLS TORQUE CHART STEERING LINKAGE DESCRIPTION TORQUE Pitman Arm Shaft ....251 N·m (185 ft. lbs.) Drag Link Ball Studs .

  • Page 716: Frame Rail

    STEERING 19 - 25 STEERING COLUMN INDEX page page DESCRIPTION AND OPERATION SPECIFICATIONS STEERING COLUMN ..... 25 TORQUE CHART ......27 REMOVAL AND INSTALLATION STEERING COLUMN .
  • Page 717 19 - 26 STEERING REMOVAL AND INSTALLATION (Continued) Fig. 1 Steering Wheel Fig. 3 Column Shrouds Fig. 2 Key Cylinder Release Access Hole (8) Remove the steering coupler bolt and column mounting nuts (Fig. 4) then lower column off the mounting studs.
  • Page 718 STEERING 19 - 27 REMOVAL AND INSTALLATION (Continued) Fig. 5 Steering Column Harness Fig. 7 Clock Spring (10) Install lower column shrouds and install mounting screws. (11) Install ignition cylinder. (12) Install knee blocker and knee blocker cover, refer to Group 8E Instrument Panel Systems. (13) Install steering wheel and tighten nut to 54 N·m (40 ft.
  • Page 720 SUSPENSION 2 - 1 SUSPENSION CONTENTS page page ALIGNMENT ......1 REAR SUSPENSION ..... . 13 FRONT SUSPENSION .
  • Page 721 2 - 2 SUSPENSION DESCRIPTION AND OPERATION (Continued) Fig. 1 Wheel Alignment Measurements...
  • Page 722 SUSPENSION 2 - 3 DIAGNOSIS AND TESTING 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 2. Tighten or replace components as suspension components.
  • Page 723 2 - 4 SUSPENSION 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.
  • Page 724 SUSPENSION 2 - 5 SERVICE PROCEDURES (Continued) (4) Adjust the left wheel toe position with the tie rod. Turn the sleeve until the left wheel is at the same TOE-IN position as the right wheel. Position the clamp bolts as shown (Fig. 3) and tighten to 27 N·m (20 ft.

  • Page 725: Frame Rail

    2 - 6 SUSPENSION FRONT SUSPENSION INDEX page page DESCRIPTION AND OPERATION SHOCK ABSORBER ..... . . 7 FRONT SUSPENSION ..... 6 STABILIZER BAR .

  • Page 726: Frame Rail

    SUSPENSION 2 - 7 DIAGNOSIS AND TESTING (Continued) ening the attaching nuts. If the noise persists, inspect for damaged and worn bushings, and attach- ing components. Repair as necessary if any of these conditions exist. A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermit- tent.

  • Page 727: Frame Rail

    2 - 8 SUSPENSION REMOVAL AND INSTALLATION (Continued) (6) Install the front propeller shaft to the axle. (7) Install drag link to pit man arm. (8) Remove the supports and lower the vehicle. (9) Tighten all suspension components to proper torque.

  • Page 728: Frame Rail

    SUSPENSION 2 - 9 REMOVAL AND INSTALLATION (Continued) (5) Install bolt 7604 through remover, bushing and (5) Remove tools and install the upper suspension receiver. arm. (6) Install Long Nut 7603 and tighten nut too pull STABILIZER BAR bushing out of the axle bracket. REMOVAL (1) Remove upper link nuts (Fig.

  • Page 729: Frame Rail

    2 - 10 SUSPENSION REMOVAL AND INSTALLATION (Continued) HUB BEARING REMOVAL (1) Raise and support the vehicle. (2) Remove the wheel and tire assembly. (3) Remove the brake caliper, rotor and ABS wheel speed sensor, refer to Group 5 Brakes. (4) Remove the cotter pin, nut retainer and axle hub nut (Fig.
  • Page 730 SUSPENSION 2 - 11 REMOVAL AND INSTALLATION (Continued) WHEEL MOUNTING STUDS (6) Install wheel and tire assembly, use new lug nut on stud or studs that were replaced. (7) Remove support and lower vehicle. REMOVAL (1) Raise and support vehicle. (2) Remove wheel and tire assembly.
  • Page 731 2 - 12 SUSPENSION SPECIAL TOOLS FRONT SUSPENSION Bolt, Special 7604 Remover/Installer Suspension Bushing 7932 Remover C-4150A Nut, Long 7603...

  • Page 732: Frame Rail

    SUSPENSION 2 - 13 REAR SUSPENSION INDEX page page DESCRIPTION AND OPERATION SHOCK ABSORBER ..... . 14 REAR SUSPENSION ..... 13 STABILIZER BAR .

  • Page 733: Frame Rail

    2 - 14 SUSPENSION (3) Connect the stabilizer bar links and shock REMOVAL AND INSTALLATION absorbers to the axle bracket. Connect the track bar to the frame rail bracket. SHOCK ABSORBER (4) Remove the supports and lower the vehicle. (5) Tighten the stabilizer bar links, shock absorb- REMOVAL ers and track bar to specified torque.

  • Page 734: Frame Rail

    SUSPENSION 2 - 15 REMOVAL AND INSTALLATION (Continued) (3) Remove the supports and lower the vehicle. (4) Remove the stabilizer bar retainer bolts and (4) Tighten the lower suspension arm nuts to 177 retainers from the axle mounts (Fig. 6) and remove N·m (130 ft.

  • Page 735: Frame Rail

    2 - 16 SUSPENSION REMOVAL AND INSTALLATION (Continued) TRACK BAR SPECIFICATIONS REMOVAL TORQUE CHART (1) Raise and support the vehicle. (2) Remove the bolt and nut from the frame rail DESCRIPTION TORQUE bracket (Fig. 7). Shock Absorber (3) Remove the bolt from the axle bracket (Fig. 7) Upper Bolts .
  • Page 736 TRANSMISSION AND TRANSFER CASE 21 - 1 TRANSMISSION AND TRANSFER CASE CONTENTS page page AUTOMATIC TRANSMISSION—30/32RH ..75 AX5 MANUAL TRANSMISSION ....1 AX15 MANUAL TRANSMISSION .

  • Page 737: General Information

    21 - 2 TRANSMISSION AND TRANSFER CASE GENERAL INFORMATION (Continued) Fig. 1 AX5 Manual Transmission Fig. 3 Fill Plug Location TRANSMISSION ASSEMBLY INFORMATION Lubricate transmission components with Fig. 2 Transmission Identification Mopar 75W–90, GL 3 gear lubricant during assem- The fill plug is on the passenger side of the bly.

  • Page 738: Diagnosis And Testing

    TRANSMISSION AND TRANSFER CASE 21 - 3 GENERAL INFORMATION (Continued) Fig. 4 Geartrain Components avoid an underfill or overfill condition. Always check the lubricant level after any addition of fluid to avoid DIAGNOSIS AND TESTING an incorrect lubricant level condition. LOW LUBRICANT LEVEL HARD SHIFTING A low transmission lubricant level is generally the...

  • Page 739: Transmission Noise

    21 - 4 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) TRANSMISSION NOISE (13) Secure transfer case, if equipped, to jack with safety chains. Most manual transmissions make some noise dur- (14) Disconnect transfer case shift linkage at ing normal operation. Rotating gears generate a mild transfer case, if equipped.
  • Page 740 TRANSMISSION AND TRANSFER CASE 21 - 5 REMOVAL AND INSTALLATION (Continued) CAUTION: It is important that the crankshaft posi- tion sensor be removed prior to transmission removal. The sensor can easily be damaged if left in place during removal operations. (18) Support engine with adjustable jack stand.
  • Page 741 21 - 6 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) (11) Install rear crossmember. Tighten crossmem- (28) Install and tighten propeller shaft U–joint ber-to-frame bolts to 41 N·m (31 ft. lbs.) torque. clamp bolts to 19 N·m (170 in. lbs.) torque. (12) Install fasteners to hold rear cushion and (29) Install slave cylinder in clutch housing.

  • Page 742: Adapter Housing Seal

    TRANSMISSION AND TRANSFER CASE 21 - 7 REMOVAL AND INSTALLATION (Continued) (3) Install new front bearing retainer gasket to the front bearing retainer. (4) Install the front bearing retainer onto the transmission case. (5) Install the bolts to hold the bearing retainer onto the transmission case.

  • Page 743: Disassembly And Assembly

    21 - 8 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) (7) Remove shift tower gasket from shift tower or transmission case (Fig. 17). Fig. 16 Remove Shift Tower Fig. 15 Install Adapter Housing Seal (3) Install transfer case. (4) Check and add fluid to transmission as neces- sary.
  • Page 744 TRANSMISSION AND TRANSFER CASE 21 - 9 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 20 Remove Detent Spring Fig. 18 Clutch Housing Fig. 21 Remove Detent Ball (15) Remove adapter/extension housing bolts. (16) Loosen adapter/extension housing by tapping it loose with plastic mallet (Fig. 26). (17) Remove adapter/extension housing (Fig.
  • Page 745 21 - 10 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 22 Shift Arm Retainer Bolt Removal Fig. 24 Removing Shift Lever Shaft Plug Fig. 23 Shift Arm Rstrictor Pins (c) Remove speedometer drive gear locating snap-ring (Fig. 28). (19) Remove the bolts holding the front bearing retainer to the transmission case.
  • Page 746 TRANSMISSION AND TRANSFER CASE 21 - 11 DISASSEMBLY AND ASSEMBLY (Continued) (21) Remove input shaft bearing snap-ring (Fig. 30). (22) Remove countershaft front bearing snap-ring. Fig. 26 Loosen Adapter/Extension Housing Fig. 29 Remove Front Bearing Retainer Fig. 27 Remove Adapter/Extension Housing–Typical Fig.
  • Page 747 21 - 12 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 31 Separate Intermediate Plate and Fig. 34 Install Transmission Gear Case to the Transmission Case Intermediate Plate (4) Install new front bearing snap rings (Fig. 35). Fig. 32 Remove Intermediate Plate from Transmission Case (3) Align geartrain and shift rails with mating holes in transmission case and install transmission...
  • Page 748 TRANSMISSION AND TRANSFER CASE 21 - 13 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 36 Install Front Bearing Retainer Fig. 38 Install Adapter/Extension Housing–Typical (8) Apply a 1/8 to 3/16 inch wide bead of Threeb- ond Liquid Gasket TB1281, P/N 83504038, to seal- ing surface of adapter/extension housing, making sure to keep sealer bead to inside of bolt holes.
  • Page 749 21 - 14 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (14) Install and tighten shifter arm shaft plug to 18 N·m (13 ft. lbs.) torque (Fig. 42). Fig. 42 Shifter Arm Shaft Plug Installation Fig. 40 Install Shifter Arm Shaft Fig.
  • Page 750 TRANSMISSION AND TRANSFER CASE 21 - 15 DISASSEMBLY AND ASSEMBLY (Continued) (18) Install detent plug and tighten to 19 N·m (14 ft. lbs.) (Fig. 46). Fig. 46 Install Detent Ball Plug Fig. 44 Install Detent Ball Fig. 47 Install Shift Tower Fig.
  • Page 751 21 - 16 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) SHIFT MECHANISM AND GEARTRAIN (3) Remove bolt holding fifth gear shift fork to shift rail (Fig. 51). DISASSEMBLY (1) Install suitable bolts and washers in intermedi- ate plate (Fig. 49). Then clamp plate and gear assem- bly in vise.
  • Page 752 TRANSMISSION AND TRANSFER CASE 21 - 17 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 53 Remove Fifth Gear Synchro Ring Fig. 55 Remove Fifth Gear Thrust Ring Fig. 54 Remove Fifth Gear and Synchro Assembly Fig. 56 Remove Fifth Gear Thrust Ring Lock Ball NOTE: There are many lock balls, check balls, interlock balls, and interlock pins used in various places in the transmission.
  • Page 753 21 - 18 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 58 Remove Output Shaft Rear Bearing Retainer Fig. 60 Remove Reverse Shift Arm Bracket Bolts Fig. 59 Remove Shift Fork To Shift Rail Bolts (14) Remove snap-ring holding output shaft rear bearing into the intermediate plate (Fig.
  • Page 754 TRANSMISSION AND TRANSFER CASE 21 - 19 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 62 Remove Countershaft and Countershaft Rear Bearing Fig. 64 Remove 3–4 Shift Fork Fig. 63 Remove Mainshaft (20) Remove the 1–2 shift fork from the 1–2 and the 3–4 shift rails (Fig. 65). (21) Remove threaded plugs from intermediate plate.
  • Page 755 21 - 20 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 68 Remove Fifth Gear Check Ball Fig. 66 Remove Lock Ball And Spring (23) Remove fifth gear shift rail (Fig. 67). Fig. 69 Remove Reverse Shift Head And Rail Assembly Fig.
  • Page 756 TRANSMISSION AND TRANSFER CASE 21 - 21 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 71 Remove Interlock Pin From Reverse Shift Rail Fig. 73 Remove 1–2 Shift Rail Interlock Pin Fig. 74 Remove 1–2 Check Ball ASSEMBLY Refer to (Fig. 75) while assembling and installing the shift rail components.
  • Page 757 21 - 22 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 75 Shift Rail Components Fig. 76 Install 1–2 Check Ball Fig. 77 Install 1–2 Shift Rail Interlock Pin (4) Install the 1–2 shift rail into the intermediate (6) Install the reverse check ball into the interme- plate.
  • Page 758 TRANSMISSION AND TRANSFER CASE 21 - 23 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 80 Install Reverse Arm Bracket to Fork Fig. 78 Install Reverse Check Ball (8) Assemble the reverse arm bracket to the reverse fork (Fig. 80). Fig. 81 Install Reverse Shift Rail Fig.
  • Page 759 21 - 24 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 83 Install Fifth Gear Check Ball Fig. 85 Install 1–2 Shift Fork Fig. 84 Install Fifth Gear Shift Rail (15) Install the shift rail detent balls in the inter- mediate plate.
  • Page 760 TRANSMISSION AND TRANSFER CASE 21 - 25 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 87 Install Shift Fork Bolts Fig. 89 Install Compression Spring And Pin (28) Position the mainshaft rear bearing retainer over the output shaft and onto the intermediate plate. (29) Install new bolts to hold the bearing retainer to the intermediate plate.
  • Page 761 21 - 26 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 91 Align Idler Shaft Pin Fig. 94 Install Fifth Gear Thrust Ring (43) Position the countershaft fifth gear assembly on the countershaft. Ensure that the fifth gear fork is installed onto the fifth gear shift rail.

  • Page 762: Countershaft

    TRANSMISSION AND TRANSFER CASE 21 - 27 DISASSEMBLY AND ASSEMBLY (Continued) COUNTERSHAFT DISASSEMBLY (1) Remove select fit snap-ring holding the coun- tershaft front bearing onto the countershaft (Fig. 96). (2) Using Bearing Splitter P-334, a suitable spacer on center of countershaft, and a shop press, remove the countershaft front bearing from the countershaft.

  • Page 763: Output Shaft

    21 - 28 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 100 Install Output Shaft Pilot Bearing Rollers OUTPUT SHAFT DISASSEMBLY (1) Remove input shaft and output shaft pilot bearing rollers from output shaft. (2) Measure and note thrust clearance of output shaft gears (Fig.
  • Page 764 TRANSMISSION AND TRANSFER CASE 21 - 29 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 102 Remove Fifth Gear Snap-ring Fig. 104 Remove First Gear Bearing Inner Race Lock Ball Fig. 103 Remove Fifth Gear, First Gear Bearing, And Fig. 105 Remove Second Gear, Reverse Gear, And Race 1–2 Synchronizer (5) Remove first gear needle roller bearing from...
  • Page 765 21 - 30 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 106 Remove 3–4 Synchronizer Snap Ring Fig. 108 Synchronizer Identification (4) Install third gear over bearing and onto output shaft flange. (5) Install third gear synchronizer ring to third gear.
  • Page 766 TRANSMISSION AND TRANSFER CASE 21 - 31 DISASSEMBLY AND ASSEMBLY (Continued) (9) Install snap-ring to hold 3–4 synchronizer onto output shaft. (10) Verify third gear thrust clearance with feeler gauge (Fig. 110). Clearance should be 0.10 – 0.25 mm (0.004 – 0.010 in.). If clearance is out of specification, refer to Cleaning and Inspection section within this group.

  • Page 767: Semi-Synchronized Reverse Idler Gear

    21 - 32 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 113 Check First–Second Gear Thrust Clearance (25) Position fifth gear onto output shaft with the gear’s short shoulder toward the rear of shaft. Ensure that the gear and output shaft splines are aligned.
  • Page 768 TRANSMISSION AND TRANSFER CASE 21 - 33 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 115 Remove Reverse Idler Gear Snap-ring Fig. 118 Remove Reverse Idler Gear Synchronizer Ring CLEANING AND INSPECTION AX5 MANUAL TRANSMISSION COMPONENTS GENERAL INFORMATION Clean the transmission components in solvent. Dry the cases, gears, shift mechanism and shafts with compressed air.
  • Page 769 21 - 34 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION (Continued) Fig. 120 Check Output Shaft Runout GEAR AND SYNCHRONIZER Install the needle bearing and inner race in the first gear. Then check oil clearance between the gear and inner race (Fig. 121). Clearance should be 0.009 –...
  • Page 770 TRANSMISSION AND TRANSFER CASE 21 - 35 CLEANING AND INSPECTION (Continued) Fig. 122 Check Gear–To–Shaft Oil Clearance Fig. 124 Check Fork–To–Hub Clearance SPECIFICATIONS TORQUE DESCRIPTION TORQUE Plugs, Access ....19 N·m (14 ft.lbs.) Bolts, Adapter Housing .
  • Page 771 21 - 36 TRANSMISSION AND TRANSFER CASE SPECIAL TOOLS 8212 Installer, Seal C-3339 Dial Indicator Set 8208 Installer, Seal C-3995-A Installer, Extension Housing Seal P-334 Splitter, Bearing 8109 Cup, Installer C-4171 Handle, Universal Tool 8211 Installer, Seal L-4507 Tube, Driver...
  • Page 772 TRANSMISSION AND TRANSFER CASE 21 - 37 SPECIAL TOOLS (Continued) 6747–1A Adapter, Fixture MD-998805 Installer, Seal...
  • Page 773 21 - 38 TRANSMISSION AND TRANSFER CASE AX15 MANUAL TRANSMISSION INDEX page page GENERAL INFORMATION DISASSEMBLY AND ASSEMBLY AX15 MANUAL TRANSMISSION ... . . 38 ADAPTER/EXTENSION HOUSING AND FRONT RECOMMENDED LUBRICANT ....39 BEARING RETAINER .
  • Page 774 TRANSMISSION AND TRANSFER CASE 21 - 39 GENERAL INFORMATION (Continued) Fig. 2 Identification Code Number Location Fig. 3 Fill Plug Location TRANSMISSION GEAR RATIOS Gear ratios for the AX15 manual transmission are as follows: • First gear: 3.83:1 • Second gear: 2.33:1 •...
  • Page 775 21 - 40 TRANSMISSION AND TRANSFER CASE GENERAL INFORMATION (Continued) Fig. 5 Output Shaft and Gears avoid an underfill or overfill condition. Always check the lubricant level after any addition of fluid to avoid DIAGNOSIS AND TESTING an incorrect lubricant level condition. LOW LUBRICANT LEVEL HARD SHIFTING A low transmission lubricant level is generally the...
  • Page 776 TRANSMISSION AND TRANSFER CASE 21 - 41 DIAGNOSIS AND TESTING (Continued) TRANSMISSION NOISE (13) Secure transfer case, if equipped, to jack with safety chains. Most manual transmissions make some noise dur- (14) Disconnect transfer case shift linkage at ing normal operation. Rotating gears generate a mild transfer case, if equipped.
  • Page 777 21 - 42 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) CAUTION: It is important that the crankshaft posi- tion sensor be removed prior to transmission removal. The sensor can easily be damaged if left in place during removal operations. (18) Support engine with adjustable jack stand.
  • Page 778 TRANSMISSION AND TRANSFER CASE 21 - 43 REMOVAL AND INSTALLATION (Continued) (11) Install rear crossmember. Tighten crossmem- (27) Align marks on front propeller shaft, axle, ber-to-frame bolts to 41 N·m (31 ft. lbs.) torque. and transfer case yokes, if equipped. (12) Install fasteners to hold rear cushion and (28) Install and tighten propeller shaft U–joint bracket to transmission.
  • Page 779 21 - 44 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) (2) Remove any residual gasket material from the sealing surfaces of the bearing retainer and the transmission case. (3) Install new front bearing retainer gasket to the front bearing retainer. (4) Install the front bearing retainer onto the transmission case.
  • Page 780 TRANSMISSION AND TRANSFER CASE 21 - 45 REMOVAL AND INSTALLATION (Continued) (7) Remove shift tower gasket from shift tower or transmission case (Fig. 18). Fig. 17 Remove Shift Tower Fig. 16 Install Adapter Housing Seal (3) Install transfer case. (4) Check and add fluid to transmission as neces- sary.
  • Page 781 21 - 46 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 21 Remove Detent Spring Fig. 19 Clutch Housing Fig. 22 Remove Detent Ball Fig. 20 Remove Detent Ball Plug (14) Remove the shift arm from the adapter hous- ing.
  • Page 782 TRANSMISSION AND TRANSFER CASE 21 - 47 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 24 Shift Arm Rstrictor Pins Fig. 25 Removing Shift Lever Shaft Plug Fig. 26 Remove Shifter Shaft Fig. 27 Adapter/Extension Housing Bolts...
  • Page 783 21 - 48 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 30 Speedometer Drive Gear Assembly Fig. 28 Loosen Adapter/Extension Housing Fig. 31 Remove Front Bearing Retainer Fig. 29 Remove Adapter/Extension Housing (18) On 4x2 transmissions; (a) Remove speedometer gear retaining snap- ring from output shaft.
  • Page 784 TRANSMISSION AND TRANSFER CASE 21 - 49 DISASSEMBLY AND ASSEMBLY (Continued) shown, making sure to keep sealer bead to inside of bolt holes (Fig. 36). (3) Align geartrain and shift rails with mating holes in transmission case and install transmission case to the intermediate plate (Fig.
  • Page 785 21 - 50 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 40 Speedometer Drive Gear Assembly Fig. 38 Install Front Bearing Snap-rings Fig. 41 Install Adapter/Extension Housing Fig. 39 Install Front Bearing Retainer (8) Apply a 1/8 to 3/16 inch wide bead of Threeb- ond Liquid Gasket TB1281, P/N 83504038, to seal- ing surface of adapter/extension housing, making sure to keep sealer bead to inside of bolt holes.
  • Page 786 TRANSMISSION AND TRANSFER CASE 21 - 51 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 43 Install Shifter Arm Shaft Fig. 45 Shifter Arm Shaft Plug Installation Fig. 44 Install Shift Arm Retainer Bolt Fig. 46 Install Shifter Restrictor Pins (15) Install shifter restrictor pins in shift tower and tighten to 27 N·m (20 ft.

  • Page 787: Shift Mechanism And Geartrain

    21 - 52 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (17) Install detent spring (Fig. 48). (20) Install new metal o-ring to the backup lamp (18) Install detent plug and tighten to 19 N·m (14 switch. ft. lbs.) (Fig. 49). (21) Install backup lamp switch (Fig.
  • Page 788 TRANSMISSION AND TRANSFER CASE 21 - 53 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 51 Positioning Intermediate Plate In Vise Fig. 54 Remove Fifth Gear Shift Fork Fig. 52 Remove Fifth Gear Snap-ring Fig. 55 Remove Reverse Shift Head Assembly Fig. 53 Remove Fifth Gear Shift Fork Retainer Bolt...
  • Page 789 21 - 54 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 58 Remove Fifth Gear And Synchro Assembly Fig. 56 Remove Fifth Gear Blocker Ring Fig. 59 Remove Fifth Gear Thrust Ring Fig. 57 Remove Fifth Gear Synchro Ring (10) Remove the countershaft fifth gear assembly from countershaft (Fig.
  • Page 790 TRANSMISSION AND TRANSFER CASE 21 - 55 DISASSEMBLY AND ASSEMBLY (Continued) (13) Remove bolts holding output shaft rear bear- ing retainer to intermediate plate (Fig. 61). Fig. 63 Remove Reverse Idler Shaft And Gear Fig. 61 Remove Output Shaft Rear Bearing Retainer Bolts (14) Remove rear bearing retainer (Fig.
  • Page 791 21 - 56 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 68 Remove Fifth Gear Shift Rail Lock Ball (21) Remove the 1–2 and 3–4 shift rail c-rings using two equally sized screwdrivers (Fig. 69). (22) Remove bolts holding 1–2 and 3–4 shift forks to the shift rails (Fig.
  • Page 792 TRANSMISSION AND TRANSFER CASE 21 - 57 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 71 Remove 3–4 Shift Rail Fig. 69 Remove Shift Rail C-rings Fig. 72 Remove 3–4 Shift Rail Interlock Plug (27) Remove the 1–2 shift rail interlock pin from the 1–2 shift rail (Fig.
  • Page 793 21 - 58 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 75 Remove 1–2 Shift Rail Interlock Pin Fig. 73 Remove Shift Forks Fig. 76 Remove 1–2 Shift Rail Interlock Plug (32) Remove the interlock pin from the reverse shift rail (Fig.
  • Page 794 TRANSMISSION AND TRANSFER CASE 21 - 59 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 79 Remove Reverse Shift Rail Interlock Pin Fig. 77 Remove Reverse Shift Rail C-ring Fig. 80 Remove Output Shaft Rear Bearing Snap-ring Fig. 78 Remove Reverse Shift Rail (36) Remove the countershaft by moving the coun- tershaft rearward until the countershaft is clear of the intermediate plate.
  • Page 795 21 - 60 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (5) Align and mesh the mainshaft and counter- (12) Install c-ring to hold the reverse shift rail into shaft gears as much as possible. the intermediate plate. (6) Install the countershaft bearing over the coun- (13) Install the 1–2 and 3–4 shift forks into the tershaft bearing boss and into the intermediate plate.
  • Page 796 TRANSMISSION AND TRANSFER CASE 21 - 61 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 86 Install 1–2 Shift Rail Interlock Pin Fig. 89 Install 3–4 Shift Rail (17) Install 3–4 shift rail interlock plug into the (19) Install new bolts to hold the shift forks to the intermediate plate (Fig.
  • Page 797 21 - 62 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (21) Install the fifth gear shift rail lock ball in the intermediate plate (Fig. 94). (22) Install the fifth gear shift rail into the inter- mediate plate. (23) Install reverse idler gear and idler gear shaft (Fig.
  • Page 798 TRANSMISSION AND TRANSFER CASE 21 - 63 DISASSEMBLY AND ASSEMBLY (Continued) (31) Position fifth gear blocker ring onto counter- shaft. Verify that blocker ring and countershaft splines are aligned. (32) Using a suitable driver and mallet, seat the blocker ring onto the countershaft. (33) Select the thickest snap-ring the will fit into the snap–ring groove of the countershaft.
  • Page 799 21 - 64 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 101 Install Reverse Shift Head And Rail Assembly Fig. 104 Install Detent Balls And Springs COUNTERSHAFT DISASSEMBLY (1) Remove select fit snap-ring holding the coun- Fig. 102 Install Fifth Gear Shift Fork tershaft front bearing onto the countershaft (Fig.
  • Page 800 TRANSMISSION AND TRANSFER CASE 21 - 65 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 107 Remove Output Shaft Pilot Bearing Fig. 105 Countershaft Front Bearing Snap-ring INPUT SHAFT DISASSEMBLY (1) Verify that the 3–4 synchronizer is in the neu- tral position. (2) Separate input shaft from output shaft (Fig. 106).
  • Page 801 21 - 66 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) DISASSEMBLY (1) Remove input shaft and output shaft pilot bearing from output shaft (Fig. 111), if necessary. (2) Measure and note thrust clearance of output shaft gears (Fig. 112). First gear clearance should be 0.10 –...
  • Page 802 TRANSMISSION AND TRANSFER CASE 21 - 67 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 112 Check Output Shaft Gear Thrust Clearance Fig. 114 Remove Fifth Gear, First Gear Bearing, And (3) Remove output shaft fifth gear snap ring with Thrust Washer two screwdrivers (Fig. 113). (5) Remove first gear thrust washer locating pin from output shaft.
  • Page 803 21 - 68 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 117 Remove 3–4 Synchronizer And Third Gear Fig. 115 Remove Second Gear And 1–2 Synchronizer/Reverse Gear Fig. 118 Synchronizer Identification (4) Install third gear over bearing and onto output shaft flange.
  • Page 804 TRANSMISSION AND TRANSFER CASE 21 - 69 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 119 Select 3–4 Synchronizer Snap-ring Fig. 121 Second Gear And Synchronizer Assembly (17) Install snap-ring to hold 1–2 synchronizer/re- verse gear onto output shaft. (18) Install first gear synchronizer ring into 1–2 synchronizer/reverse gear.

  • Page 805: Cleaning And Inspection

    21 - 70 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 122 First And Fifth Gear Components Fig. 124 Select/Install Fifth Gear Snap Ring CLEANING AND INSPECTION AX15 MANUAL TRANSMISSION COMPONENTS GENERAL INFORMATION Clean the transmission components in solvent. Dry the cases, gears, shift mechanism and shafts with compressed air.
  • Page 806 TRANSMISSION AND TRANSFER CASE 21 - 71 CLEANING AND INSPECTION (Continued) Inspect the threads in the case, housing, and plate. Minor thread damage can be repaired with steel thread inserts, if necessary. Do not attempt to repair any threads which show evidence of cracks around the threaded hole.

  • Page 807: Specifications

    21 - 72 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION (Continued) SPECIFICATIONS TORQUE DESCRIPTION TORQUE Plugs, Access ....19 N·m (14 ft.lbs.) Bolts, Adapter Housing ..34 N·m (25 ft.lbs.) Switch, Back-up Light .

  • Page 808: Special Tools Ax5

    TRANSMISSION AND TRANSFER CASE 21 - 73 SPECIAL TOOLS AX15 8208 Installer, Seal C-3339 Dial Indicator Set L-4407A Puller, Gear C-4171 Handle, Universal Tool P-334 Splitter, Bearing 8209 Installer, Seal 8109 Cup, Installer 8212 Installer, Seal...
  • Page 809 21 - 74 TRANSMISSION AND TRANSFER CASE SPECIAL TOOLS (Continued) 6052 Tube, Driver MD-998805 Tube, Driver 6761 Adapter, Installer L-4507 Tube, Driver...
  • Page 810 TRANSMISSION AND TRANSFER CASE 21 - 75 AUTOMATIC TRANSMISSION—30/32RH INDEX page page GENERAL INFORMATION PARK LOCK ......105 30/32RH AUTOMATIC TRANSMISSION .
  • Page 811 21 - 76 TRANSMISSION AND TRANSFER CASE (1) A result of restricted fluid flow through the GENERAL INFORMATION main and/or auxiliary cooler. This condition is usu- ally the result of a faulty or improperly installed 30/32RH AUTOMATIC TRANSMISSION drainback valve, a damaged main cooler, or severe The 30RH automatic transmission is used with the restrictions in the coolers and lines caused by debris 2.5L engine.
  • Page 812 TRANSMISSION AND TRANSFER CASE 21 - 77 GENERAL INFORMATION (Continued) Fig. 1 30/32 RH Automatic Transmission...
  • Page 813 21 - 78 TRANSMISSION AND TRANSFER CASE GENERAL INFORMATION (Continued) GEARSHIFT MECHANISM The shift mechanism is cable operated and pro- vides six shift positions. The shift indicator is located on the console next to the gear shift. The shift posi- tions are: •...
  • Page 814 TRANSMISSION AND TRANSFER CASE 21 - 79 DESCRIPTION AND OPERATION (Continued) The 1-2 shift valve provide 1-2 and 2-1 shifts and CONVERTER CLUTCH ENGAGEMENT the 2-3 shift valve provide 2-3 and 3-2 shifts. Converter clutch engagement in third gear is con- The 1-2 shift control valve transmits 1-2 shift pres- trolled by sensor inputs to the powertrain control sure to the accumulator piston.
  • Page 815 21 - 80 TRANSMISSION AND TRANSFER CASE DESCRIPTION AND OPERATION (Continued) Fig. 3 Ignition Interlock Cable Routing PRELIMINARY DIAGNOSIS Two basic procedures are required. One procedure for vehicles that are drivable and an alternate proce- dure for disabled vehicles (will not back up or move forward).
  • Page 816 TRANSMISSION AND TRANSFER CASE 21 - 81 DIAGNOSIS AND TESTING (Continued) (3) Check for cracked, leaking cooler lines, or loose (d) NEUTRAL position—Engine running and or missing pressure-port plugs. brakes applied, apply forward force on center of (4) Raise and support vehicle on safety stands, shift handle.
  • Page 817 21 - 82 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) required, the 300 psi gauge can be used at any of the other test ports. Pressure Test Port Locations Pressure test ports locations are provided at the accumulator, front servo, and rear servo, governor passage, and overdrive clutch pressure passage (Fig.
  • Page 818 TRANSMISSION AND TRANSFER CASE 21 - 83 DIAGNOSIS AND TESTING (Continued) PRESSURE TEST PROCEDURE (4) Read pressures on both gauges as transmission throttle lever is moved from full forward to full rear- Test One - Transmission In 1 Range ward position. (5) Line pressure should be 54-60 psi (372-414 This test checks pump output, pressure regulation, kPa) with throttle lever forward and gradually...
  • Page 819 21 - 84 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) CAUTION: Stalling the converter causes a rapid increase in fluid temperature. To avoid fluid over- heating, hold the engine at maximum rpm for no more than 5 seconds. If engine exceeds 2500 rpm during the test, release the accelerator pedal imme- diately;...
  • Page 820 TRANSMISSION AND TRANSFER CASE 21 - 85 DIAGNOSIS AND TESTING (Continued) Some suspected converter housing fluid leaks may not be leaks at all. They may only be the result of residual fluid in the converter housing, or excess fluid spilled during factory fill or fill after repair. Converter housing leaks have several potential sources.
  • Page 821 21 - 86 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) CONVERTER HOUSING AREA LEAK CORRECTION (7) Adjust front band. (8) Lubricate pump seal and converter hub with (1) Remove converter. transmission fluid or petroleum jelly and install con- (2) Tighten front band adjusting screw until band verter.
  • Page 822 TRANSMISSION AND TRANSFER CASE 21 - 87 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION DELAYED ENGAGEMENT 1. Fluid Level Low. 1. Correct level and check for leaks. FROM NEUTRAL TO 2. Filter Clogged. 2. Change filter. DRIVE OR REVERSE 3.
  • Page 823 21 - 88 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION NO DRIVE OR REVERSE 1. Fluid Level Low. 1. Add fluid and check for leaks if drive is (VEHICLE WILL NOT restored. MOVE) 2. Gearshift Linkage/Cable 2.
  • Page 824 TRANSMISSION AND TRANSFER CASE 21 - 89 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION SHIFTS DELAYED OR 1. Fluid Level Low/High. 1. Correct fluid level and check for leaks if ERRATIC (SHIFTS ALSO low. HARSH AT TIMES) 2. Throttle Linkage Misadjusted. 2.
  • Page 825 21 - 90 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION NO LOW GEAR (MOVES 1. Governor Valve Sticking. 1. Remove governor, clean, inspect and IN 2ND OR 3RD GEAR repair as required. ONLY) 2. Valve Body Malfunction. 2.
  • Page 826 TRANSMISSION AND TRANSFER CASE 21 - 91 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION BUZZING NOISE 1. Fluid Level Low. 1. Add fluid and check for leaks. 2. Shift Cable Misassembled. 2. Route cable away from engine and bell housing.
  • Page 827 21 - 92 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION GROWLING, GRATING OR 1. Drive Plate Broken. 1. Replace. SCRAPING NOISES 2. Torque Converter Bolts Hitting 2. Dust shield bent. Replace or repair. Dust Shield. 3.
  • Page 828 TRANSMISSION AND TRANSFER CASE 21 - 93 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION NO START IN PARK OR 1. Gearshift Linkage/Cable 1. Adjust linkage/cable. NEUTRAL Misadjusted. 2. Neutral Switch Wire Open/Cut. 2. Check continuity with test lamp. Repair as required.
  • Page 829 21 - 94 TRANSMISSION AND TRANSFER CASE REMOVAL SERVICE PROCEDURES (1) Hoist and support vehicle on safety stands. FLUID LEVEL CHECK (2) Place a large diameter shallow drain pan beneath the transmission pan. Transmission fluid level should be checked monthly (3) Remove bolts holding front and sides of pan to under normal operation.
  • Page 830 TRANSMISSION AND TRANSFER CASE 21 - 95 SERVICE PROCEDURES (Continued) INSPECTION is equal on both sides of the dipstick. If one side is noticably higher than the other, the dipstick has Inspect bottom of pan and magnet for excessive picked up some oil from the dipstick tube. Allow the amounts of metal or fiber contamination.
  • Page 831 21 - 96 TRANSMISSION AND TRANSFER CASE SERVICE PROCEDURES (Continued) (1) Disconnect the From cooler line at the trans- nents. DO NOT use solvents containing acids, water, mission and place a collecting container under the gasoline, or any other corrosive liquids. disconnected line.
  • Page 832 TRANSMISSION AND TRANSFER CASE 21 - 97 SERVICE PROCEDURES (Continued) Heli-Coil, or equivalent, tools and inserts are readily available from most automotive parts suppli- ers. REMOVAL AND INSTALLATION TRANSMISSION CAUTION: The transmission and torque converter must be removed as an assembly to avoid compo- nent damage.
  • Page 833 21 - 98 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) (21) Remove bolts attaching crossmember to frame (8) Position transmission on jack and secure it and remove crossmember. with safety chains. (22) Disconnect transfer case vent hose. Then dis- (9) Check condition converter...
  • Page 834 TRANSMISSION AND TRANSFER CASE 21 - 99 REMOVAL AND INSTALLATION (Continued) Fig. 19 Transmission Attachment (32) Adjust gearshift linkage and throttle valve (3) Pull the torque converter forward until the cen- cable if necessary. ter hub clears the oil pump seal. (33) Align and connect propeller shaft(s).
  • Page 835 21 - 100 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) (6) Check converter seating with a scale and straightedge (Fig. 20). Surface of converter lugs should be 1/2 in. to rear of straightedge when con- verter is fully seated. (7) If necessary, temporarily secure converter with C-clamp attached to the converter housing.
  • Page 836 TRANSMISSION AND TRANSFER CASE 21 - 101 REMOVAL AND INSTALLATION (Continued) Fig. 22 Speedometer Pinion Adapter Components (2) Install new O-rings on speed sensor and speed- ometer adapter if necessary (Fig. 22). (3) Lubricate sensor and adapter O-rings with transmission fluid. (4) Install vehicle speed sensor in speedometer adapter.
  • Page 837 21 - 102 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) (2) Remove lower steering column shroud. Refer to Group 19, Steering, for proper procedure. (3) Remove tie strap near the solenoid retaining the brake transmission interlock cable to the steering column.
  • Page 838 TRANSMISSION AND TRANSFER CASE 21 - 103 REMOVAL AND INSTALLATION (Continued) Fig. 26 Cable and Shifter (11) Install lower steering column shroud and igni- tion lock. (12) Install lower steering column cover. VALVE BODY REMOVAL (1) Raise vehicle. (2) Remove oil pan and drain fluid. (3) Loosen clamp bolts and remove throttle and manual valve levers from manual lever shaft.
  • Page 839 21 - 104 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) (14) Connect park/neutral position switch and con- verter clutch solenoid wires. (15) Install speedometer pinion gear, adapter and speed sensor. (16) Lower vehicle. (17) Fill transmission with Mopar ATF Plus 3, Type 7176 fluid.
  • Page 840 TRANSMISSION AND TRANSFER CASE 21 - 105 REMOVAL AND INSTALLATION (Continued) Fig. 31 Governor Valve Fig. 33 Governor Body (10) Remove governor valve and shaft from gover- (a) Install thin snap ring first. Then install nor body (Fig. 31). thrust washer second, and thick snap ring last (11) Remove snap rings and spacer that retain (Fig.
  • Page 841 21 - 106 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) end of control rod for wear grooves, or being seized on rod. Replace rod if bent, if knob is worn/grooved, or it has seized on rod. Replace park gear if lugs are damaged.
  • Page 842 TRANSMISSION AND TRANSFER CASE 21 - 107 DISASSEMBLY AND ASSEMBLY (Continued) VALVE BODY DISASSEMBLY Position the valve body on a clean work surface to avoid contamination. CAUTION: Do not clamp any part of the valve body assembly (Fig. 39) in a vise. This practice will dis- tort the valve body and transfer plate resulting in valve bind.
  • Page 843 21 - 108 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 40 Adjusting Screw Bracket, Springs, Valve Fig. 43 Manual Valve Removal (13) Remove screws attaching end cover plate to torque converter module (Fig. 47). (14) Remove converter clutch valve, fail safe valve, and springs (Fig.
  • Page 844 TRANSMISSION AND TRANSFER CASE 21 - 109 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 45 Converter Clutch Solenoid Fig. 48 Valve Body Transfer Plate Screws (20) Note position of filter, rear clutch servo and rear servo check balls for assembly reference (Fig. 49) and (Fig.
  • Page 845 21 - 110 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (23) Remove governor plug end plate (Fig. 53). (24) Remove 1-2 and 2-3 shift valve governor plugs from valve body (Fig. 53). (25) Remove shuttle valve throttle plug, primary spring and shuttle valve from valve body (Fig.
  • Page 846 TRANSMISSION AND TRANSFER CASE 21 - 111 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 53 Control Valves, Shift Valves, And Governor Plugs (5) Compress spring into kickdown limit valve (18) Assemble shuttle valve spring and guides body. (Fig. 53). Place spring and guides in position on shut- (6) Install retainer in grooves at end of kickdown tle valve stem.
  • Page 847 21 - 112 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 55 Shuttle Valve End Plate Fig. 57 Transfer And Separator Plates (22) Install rear clutch servo and rear servo check balls in proper cavities in transfer plate (Fig. 56). (23) Insert filter into opening in separator plate (Fig.
  • Page 848 TRANSMISSION AND TRANSFER CASE 21 - 113 DISASSEMBLY AND ASSEMBLY (Continued) (38) Install screw to attach solenoid to transfer plate (Fig. 62). (39) If necessary, insert park rod end into manual lever and install E-clip (Fig. 63). Fig. 62 Converter Clutch Solenoid Fig.
  • Page 849 21 - 114 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 64 Securing Detent Ball And Spring With Retainer Tool Fig. 67 Manual Valve And Throttle Lever Alignment Fig. 65 Manual Valve Fig. 68 Adjusting Screw Bracket, Springs, and Valves (3) Clean exterior of transmission with suitable solvent or pressure washer.
  • Page 850 TRANSMISSION AND TRANSFER CASE 21 - 115 DISASSEMBLY AND ASSEMBLY (Continued) (14) Thread bolts of Slide Hammer Tools C-3752 into threaded holes in pump body flange (Fig. 73). (15) Bump slide hammer weights outward to remove pump and reaction shaft support assembly from case (Fig.
  • Page 851 21 - 116 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 74 Front Band Strut (21) Remove output shaft thrust plate and washer from output shaft hub (Fig. 77). (22) Remove front band from case (Fig. 78). (23) Remove extension housing from transmission case.
  • Page 852 TRANSMISSION AND TRANSFER CASE 21 - 117 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 78 Front Band Fig. 80 Rear Band Adjuster Location Fig. 79 Planetary Geartrain Fig. 81 Low-Reverse Drum Snap Ring (28) Remove bolts attaching rear support to trans- mission case and pull support from low-reverse drum (Fig.
  • Page 853 21 - 118 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 85 Rear Band and Link—30RH Fig. 83 Overrunning Clutch Cam Bolt Locations Fig. 86 Rear Band and Link—30RH (d) Using snap-ring plier, pull rear band lever pivot from transmission case (Fig. 90). (e) Separate rear band servo lever from trans- mission.
  • Page 854 TRANSMISSION AND TRANSFER CASE 21 - 119 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 89 Front Band Lever Fig. 91 Compressing Front Servo Fig. 90 Rear Band Servo Lever Pin (33) Compress front servo rod guide about 1/8 in. with large C-clamp and Tool C-4470, or Spring Com- pressor Tool C-3422-B (Fig.
  • Page 855 21 - 120 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (a) Assemble link bar to band. Notched side of link toward band (Fig. 90). (b) Insert rear band through pan opening in transmission case. (c) Insert hook on band onto adjuster lever. (d) Align holes in link bar with hole in transmis- sion case outboard of rear support opening (Fig.
  • Page 856 TRANSMISSION AND TRANSFER CASE 21 - 121 DISASSEMBLY AND ASSEMBLY (Continued) (22) Align drive lugs on rear planetary gear with slots in low-reverse drum (Fig. 96). Then seat plane- tary assembly in drum. (23) Install governor on output shaft. Fig. 98 Front and Rear Clutches (26) Install output shaft thrust plate on shaft hub in planetary geartrain driving shell (Fig.
  • Page 857 21 - 122 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) annulus gear. Verify that front clutch drive lugs are fully engaged in slots of driving shell after installa- tion. Fig. 100 Assembling Front And Rear Clutch Units Fig. 103 Front Band Fig.
  • Page 858 TRANSMISSION AND TRANSFER CASE 21 - 123 DISASSEMBLY AND ASSEMBLY (Continued) (40) Lubricate oil pump seals with Mopar Door- Ease, or Ru-Glyde, Door Eze, or ATF Plus 3. (41) Install oil pump (Fig. 109). Align and position pump on pilot studs. Slide pump down studs and work it into front clutch hub and case by hand.
  • Page 859 21 - 124 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) NOTE: If end play is incorrect, transmission is incorrectly assembled, output shaft thrust washer and/or thrust plate are worn and need to be changed. (a) Attach dial indicator (C-3339) to converter housing.
  • Page 860 TRANSMISSION AND TRANSFER CASE 21 - 125 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 113 Assembling Overrunning Clutch And Cam Fig. 115 Assembled Overrunning Clutch Fig. 114 Temporary Assembly Of Clutch And Drum Fig. 116 Front Servo To Check Operation REAR SERVO PISTON (3) Remove and discard servo component O-ring and seal rings.
  • Page 861 21 - 126 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (6) If pump seal was not removed during transmis- sion disassembly, remove seal with punch and ham- mer. (7) Remove front clutch thrust washer from sup- port hub (Fig. 122). Fig.
  • Page 862 TRANSMISSION AND TRANSFER CASE 21 - 127 DISASSEMBLY AND ASSEMBLY (Continued) (3) Stake new pump bushing in two places with (4) Lightly grip old bushing in vise or with pliers blunt punch (Fig. 124). Remove burrs from stake and back remover tool out of bushing. points with knife blade afterward.
  • Page 863 21 - 128 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (8) Install reaction shaft support on pump housing (Fig. 129). (9) Align reaction support on pump housing. Use alignment marks made at disassembly. Or, rotate support until bolt holes in support and pump housing are all aligned (holes are offset for one-way fit).
  • Page 864 TRANSMISSION AND TRANSFER CASE 21 - 129 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 131 Front Clutch Components FRONT CLUTCH DISASSEMBLY (1) Remove waved snap ring and remove pressure plate, clutch plates and clutch discs (Fig. 131). (2) Compress clutch piston spring with Compressor Tool C-3575-A (Fig.
  • Page 865 21 - 130 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) CAUTION: Never push the clutch piston straight in. (7) Compress piston spring and retainer with Com- This will fold the seals over causing leakage and pressor Tool C-3575-A (Fig. 132). Then install new snap ring to secure spring retainer and spring.
  • Page 866 TRANSMISSION AND TRANSFER CASE 21 - 131 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 137 Rear Clutch Components ASSEMBLY (6) Remove and discard piston seals. (7) Remove input shaft snap-ring (Fig. 138). It (1) Soak clutch discs in transmission fluid while may be necessary to press the input shaft in slightly assembling other clutch parts.
  • Page 867 21 - 132 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) CAUTION: Never push the clutch piston straight in. This will fold the seals over causing leakage and clutch slip. In addition, never use any type of metal tool to help ease the piston seals into place. Metal tools will cut, shave, or score the seals.
  • Page 868 TRANSMISSION AND TRANSFER CASE 21 - 133 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 144 Installing Rear Clutch Thrust Washer Fig. 142 Piston Spring/Wave Spring Position (6) Remove front planetary gear front thrust • .083–.085 in. washer from annulus gear hub. • .076–.078 in. (7) Separate and remove driving shell, rear plane- •...
  • Page 869 21 - 134 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (5) Install assembled rear planetary and annulus gear on output shaft (Fig. 150). Verify that assembly is fully seated on shaft. (6) Install front thrust washer on rear planetary gear (Fig.
  • Page 870 TRANSMISSION AND TRANSFER CASE 21 - 135 DISASSEMBLY AND ASSEMBLY (Continued) (11) Align rear thrust plate on driving shell and install sun gear lock ring. Be sure ring is fully seated in sun gear ring groove (Fig. 156). (12) Install assembled driving shell and sun gear on output shaft (Fig.
  • Page 871 21 - 136 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) (19) Install thrust washer in front annulus (Fig. 161). Align flat on washer with flat on planetary hub. Also be sure washer tab is facing up. (20) Install front annulus snap ring (Fig. 162). Use snap ring pliers to avoid distorting ring during installation.
  • Page 872 TRANSMISSION AND TRANSFER CASE 21 - 137 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 161 Installing Front Annulus Thrust Washer Fig. 164 Checking Planetary Geartrain End Play CLEANING AND INSPECTION GOVERNOR AND PARK GEAR Thoroughly clean all the governor parts in a suit- able cleaning solution but do not use any type of caustic cleaning agents.
  • Page 873 21 - 138 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION (Continued) Fig. 165 Governor Weights Fig. 166 Governor Components and reaction plug (Fig. 168). Compress the reac- and install it. Do not distort the clip during tion plug spring clip only enough to remove removal or installation.
  • Page 874 TRANSMISSION AND TRANSFER CASE 21 - 139 CLEANING AND INSPECTION (Continued) Be sure a replacement sprag is installed so the sprag locking lug will face the park gear (Fig. 169). Also be sure the spring is correctly positioned as shown (Fig. 169). The sprag may not retract if the spring is improperly installed.
  • Page 875 21 - 140 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION (Continued) or any surfaces are heavily scored, the valve body scored. Inspect all of the valve body springs. The will have to be replaced. springs must be free of distortion, warpage or broken coils.
  • Page 876 TRANSMISSION AND TRANSFER CASE 21 - 141 CLEANING AND INSPECTION (Continued) Inspect the case for cracks, porous spots, worn Replace the low-reverse drum if the clutch race, servo bores, or damaged threads. However, the case roller surface or inside diameter is scored, worn or will have to be replaced if it exhibits damage or wear.
  • Page 877 21 - 142 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION (Continued) FRONT CLUTCH Clean and inspect the front clutch components. Replace the clutch discs if warped, worn, scored, burned or charred, or if the facing is flaking off. Replace the steel plates if heavily scored, warped, or broken.
  • Page 878 TRANSMISSION AND TRANSFER CASE 21 - 143 CLEANING AND INSPECTION (Continued) planetary thrust plates and the tabbed thrust wash- ers if cracked, scored or worn. Inspect the machined surfaces of the output shaft. Be sure the oil passages are open and clear. Replace the shaft if scored, pitted, or damaged.
  • Page 879 21 - 144 TRANSMISSION AND TRANSFER CASE ADJUSTMENTS (Continued) (7) Check adjustment as follows: (a) Check movement of release shift handle but- ton (floor shift) or release lever (column shift). You should not be able to press button inward or move column lever.
  • Page 880 TRANSMISSION AND TRANSFER CASE 21 - 145 ADJUSTMENTS (Continued) Checking Throttle Valve Cable Adjustment (5) Insert a small screwdriver under edge of retaining clip and remove retaining clip. (1) Turn ignition key to OFF position. (6) Center cable end on attachment stud to within (2) Remove air cleaner.
  • Page 881 21 - 146 TRANSMISSION AND TRANSFER CASE ADJUSTMENTS (Continued) Fig. 180 Band Adjustment Adapter Tool REAR BAND ADJUSTMENT The transmission oil pan must be removed for access to the rear band adjusting screw. (1) Raise vehicle. (2) Remove transmission oil pan and drain fluid. (3) Loosen band adjusting screw locknut 5-6 turns.
  • Page 882 TRANSMISSION AND TRANSFER CASE 21 - 147 ADJUSTMENTS (Continued) Push the gauge tool inward to compress the kick- down valve against the spring and bottom the throt- tle valve. Maintain pressure against kickdown valve spring. Turn throttle lever stop screw until the screw head touches throttle lever tang and the throttle lever cam touches gauge tool.
  • Page 883 21 - 148 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS (Continued)
  • Page 884 TRANSMISSION AND TRANSFER CASE 21 - 149 SCHEMATICS AND DIAGRAMS (Continued)
  • Page 885 21 - 150 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS (Continued)
  • Page 886 TRANSMISSION AND TRANSFER CASE 21 - 151 SCHEMATICS AND DIAGRAMS (Continued)
  • Page 887 21 - 152 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS (Continued)
  • Page 888 TRANSMISSION AND TRANSFER CASE 21 - 153 SCHEMATICS AND DIAGRAMS (Continued)
  • Page 889 21 - 154 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS (Continued)
  • Page 890 TRANSMISSION AND TRANSFER CASE 21 - 155 SCHEMATICS AND DIAGRAMS (Continued)
  • Page 891 21 - 156 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS (Continued)
  • Page 892 TRANSMISSION AND TRANSFER CASE 21 - 157 SCHEMATICS AND DIAGRAMS (Continued)
  • Page 893 21 - 158 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS (Continued)
  • Page 894 TRANSMISSION AND TRANSFER CASE 21 - 159 SCHEMATICS AND DIAGRAMS (Continued)
  • Page 895 21 - 160 TRANSMISSION AND TRANSFER CASE SPECIFICATIONS 30/32RH AUTOMATIC TRANSMISSION GENERAL COMPONENT METRIC INCH Oil pump gear tip clearance 0.089-0.190 mm 0.0035-0.0075 in. Planetary end play 0.125-1.19 mm 0.001-0.047 in. Input shaft end play 0.56-2.31 mm 0.022-0.091 in. Clutch pack clearance/Front 4-disc. 1.70-3.40 mm 0.067-0.134 in.
  • Page 896 TRANSMISSION AND TRANSFER CASE 21 - 161 SPECIFICATIONS (Continued) PRESSURE TEST—ALL ITEM RANGE PRESSURE Line pressure (at Closed throttle 372-414 kPa (54-60 psi). accumulator) Front servo Third gear only No more than 21 kPa (3 psi) lower than line pressure. Rear servo 1 range No more than 21 kPa (3 psi) lower than line pressure.
  • Page 897 21 - 162 TRANSMISSION AND TRANSFER CASE SPECIAL TOOLS (Continued) Pilot Stud—C-3288-B Spring Compressor—C-3422-B Pressure Gauge—C-3292 Fixture, Engine Support—C-3487-A Pressure Gauge—C-3293SP Spring Compressor—C-3575-A Dial Indicator—C-3339 Spring Compressor—C-3863-A...
  • Page 898 TRANSMISSION AND TRANSFER CASE 21 - 163 SPECIAL TOOLS (Continued) Adapter, Band Adjuster—C-3705 Seal Installer—C-3860-A Transmission Repair Stand—C-3750-B Bushing Remover/Installer—C-3887-J Puller, Slide Hammer—C-3752 Cup, Remover—SP-3633 Gauge, Throttle Setting—C-3763 Remover, Bushing—SP-5301...
  • Page 899 21 - 164 TRANSMISSION AND TRANSFER CASE SPECIAL TOOLS (Continued) Installer, Bushing—SP-5118 Installer, Bushing—SP-5511 Installer, Bushing—SP-5302 Snap-ring Plier—C-3915 Remover, Bushing—SP-3550 Seal Remover—C-3985-B Remover, Bushing—SP-3629 Bushing, Remover—6957...
  • Page 900 TRANSMISSION AND TRANSFER CASE 21 - 165 SPECIAL TOOLS (Continued) Flusher, Oil Cooler—6906 Universal Handle—C-4171 Installer—C-3995-A Remover/Installer—C-4470 Nut, Bushing Remover—SP-1191...
  • Page 901 21 - 166 TRANSMISSION AND TRANSFER CASE NV231 TRANSFER CASE INDEX page page GENERAL INFORMATION DISASSEMBLY AND ASSEMBLY NV231 TRANSFER CASE ....166 NV231 TRANSFER CASE ....170 RECOMMENDED LUBRICANT AND FILL LEVEL .
  • Page 902 TRANSMISSION AND TRANSFER CASE 21 - 167 GENERAL INFORMATION (Continued) RECOMMENDED LUBRICANT AND FILL LEVEL The fill and drain plugs are both in the rear case (Fig. 1). Correct fill level is to the bottom edge of the Recommended lubricant for the NV231 transfer fill plug hole.
  • Page 903 21 - 168 TRANSMISSION AND TRANSFER CASE (6) Connect vehicle speed sensor wires, and vent REMOVAL AND INSTALLATION hose. (7) Connect indicator switch harness to transfer TRANSFER CASE case switch, if necessary. Secure wire harness to clips on transfer case. REMOVAL (8) Align and connect propeller shafts.
  • Page 904 TRANSMISSION AND TRANSFER CASE 21 - 169 REMOVAL AND INSTALLATION (Continued) Fig. 3 Shift Linkage SPEEDOMETER (3) Lubricate sensor and adapter O-rings with transmission fluid. (4) Install vehicle speed sensor in speedometer REMOVAL adapter. Tighten sensor attaching screw to 2-3 N·m (1) Raise vehicle.
  • Page 905 21 - 170 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION (Continued) Fig. 4 Speedometer Components Fig. 6 Remove Front Output Shaft Seal Fig. 5 Location Of Index Numbers On Speedometer Adapter DISASSEMBLY AND ASSEMBLY (2) Remove front propeller shaft. Refer to Group 3, NV231 TRANSFER CASE Differential and Driveline, for proper procedure.
  • Page 906 TRANSMISSION AND TRANSFER CASE 21 - 171 DISASSEMBLY AND ASSEMBLY (Continued) (6) Use a suitable pry tool, or a slide hammer mounted screw, to remove the seal from the rear retainer (Fig. 10). (7) Remove the rear output bearing I.D. retaining ring (Fig.
  • Page 907 21 - 172 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) positioned on yoke and not on slinger as slinger will be damaged. Fig. 12 Rear Retainer Removal Fig. 15 Yoke Nut Removal Fig. 13 Oil Pump Removal Fig. 16 Yoke Removal (4) Remove seal washer from front output shaft.
  • Page 908 TRANSMISSION AND TRANSFER CASE 21 - 173 DISASSEMBLY AND ASSEMBLY (Continued) FRONT OUTPUT SHAFT AND DRIVE CHAIN REMOVAL (1) Support transfer case so rear case is facing upward. (2) Remove bolts holding front case to rear case. The case alignment bolts require flat washers (Fig. 18).
  • Page 909 21 - 174 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 25 Range Fork And Hub Removal Fig. 23 Detent Plug, Spring And Plunger Removal (3) Remove mode fork and sleeve as an assembly (Fig. 24). Note position of sleeve for assembly refer- ence.
  • Page 910 TRANSMISSION AND TRANSFER CASE 21 - 175 DISASSEMBLY AND ASSEMBLY (Continued) (2) Remove front bearing retainer. Pry retainer loose with pry tool positioned in slots at each end of retainer (Fig. 32). Fig. 28 Mode Hub Retaining Ring Removal Fig. 31 Front Bearing Retainer Bolts Fig.
  • Page 911 21 - 176 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 33 Removing Input Gear Retaining Ring Fig. 35 Input Gear Snap-Ring Removal Fig. 36 Input Gear Retainer Removal Fig. 34 Input Gear And Planetary Carrier Removal INPUT AND LOW RANGE GEAR DISASSEMBLY (1) Remove snap-ring that retains input gear in low range gear (Fig.
  • Page 912 TRANSMISSION AND TRANSFER CASE 21 - 177 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 38 Input Gear Removal Fig. 40 Front Output Seal Removal Fig. 39 Rear Tabbed Thrust Washer Removal Fig. 41 Front Output Shaft Bearing Retaining Ring Removal (1) Remove the front output shaft seal from case with pry tool (Fig.
  • Page 913 21 - 178 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 43 Front Output Shaft Bearing Installation Fig. 46 Output Shaft Rear Bearing Removal Fig. 44 Installing Output Shaft Front Bearing Retaining Ring Fig. 47 Output Shaft Rear Bearing Installation (9) Using Remover C-4210 and Handle C-4171, Fig.
  • Page 914 TRANSMISSION AND TRANSFER CASE 21 - 179 DISASSEMBLY AND ASSEMBLY (Continued) gear and driving the bearing out with the drift and a hammer (Fig. 51). (14) Install new pilot bearing with Installer 5065 and Handle C-4171 (Fig. 52). Fig. 48 Output Shaft Rear Bearing Installation Depth Fig.
  • Page 915 21 - 180 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 55 Installing Rear Bearing In Retainer (3) Install input gear in low range gear. Be sure input gear is fully seated. (4) Install remaining thrust washer in low range gear and on top of input gear.
  • Page 916 TRANSMISSION AND TRANSFER CASE 21 - 181 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 57 Input/Low Range Gear Installation Fig. 59 Install Front Bearing Retainer (4) Install mode hub retaining ring. Verify that the retaining ring is fully seated in mainshaft groove. SHIFT FORKS AND MAINSHAFT INSTALLATION (1) Install new sector shaft O-ring and bushing (Fig.
  • Page 917 21 - 182 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 64 Mainshaft Assembly Installation Fig. 61 Shift Sector Installation Fig. 62 Range Lever Installation Fig. 65 Assembling Mode Fork And Sleeve (5) Align and insert range fork pin in shift sector (9) Install assembled mode fork and sleeve (Fig.
  • Page 918 TRANSMISSION AND TRANSFER CASE 21 - 183 DISASSEMBLY AND ASSEMBLY (Continued) (13) Install detent plunger, spring and plug (Fig. 67). (14) Verify that plunger is properly engaged in sec- tor. Fig. 69 Install Mode Fork Spring OIL PUMP AND REAR CASE ASSEMBLY/INSTALLATION (1) Install magnet in front case pocket (Fig.
  • Page 919 21 - 184 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 71 Pickup Tube O-Ring Position Fig. 74 Range Lever Installation (3) Install new seal washer on front output shaft (Fig. 76). (4) Lubricate yoke hub with transmission fluid and install yoke on front shaft.
  • Page 920 TRANSMISSION AND TRANSFER CASE 21 - 185 DISASSEMBLY AND ASSEMBLY (Continued) REAR RETAINER INSTALLATION (1) Apply bead of Mopar Sealer P/N 82300234, or Loctite Ultra Gray, to mating surface of rear retainer. Sealer bead should be a maximum of 3/16 inch.
  • Page 921 21 - 186 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION (Continued) Fig. 80 Mainshaft, Mode Hub, And Drive Sprocket Fig. 81 Input Gear And Carrier Components SHIFT FORKS/HUBS/SLEEVES Check both of the sleeves for wear or damage, especially on the interior teeth. Replace the sleeves if Check condition of the shift forks and mode fork wear or damage is evident.
  • Page 922 TRANSMISSION AND TRANSFER CASE 21 - 187 CLEANING AND INSPECTION (Continued) aged, bearing surfaces are scored, or if any sprocket teeth are cracked or broken. Examine the drive chain and shaft bearings. Replace the chain and both sprockets if the chain is stretched, distorted, or if any of the links bind.
  • Page 923 21 - 188 TRANSMISSION AND TRANSFER CASE ADJUSTMENTS (Continued) Fig. 84 Rear Retainer Components Fig. 85 Seal Contact Surface Of Yoke Slinger Fig. 86 Low Range Annulus Gear...
  • Page 924 TRANSMISSION AND TRANSFER CASE 21 - 189 ADJUSTMENTS (Continued) SPECIAL TOOLS NV231 Installer—C-4076-B Puller, Slinger—MD-998056–A Fig. 87 Shift Linkage SPECIFICATIONS TORQUE DESCRIPTION TORQUE Plug, Detent ..16–24 N·m (12–18 ft. lbs.) Plug, Drain/Fill .
  • Page 925 21 - 190 TRANSMISSION AND TRANSFER CASE SPECIAL TOOLS (Continued) Installer, Boot Clamp—C-4975-A Installer, Bearing—5064 Installer, Seal—8143 Installer, Bearing—5065 Installer, Bushing—5066 Handle, Universal—C-4171 Installer, Bearing—8128 Installer, Seal—C-4210...
  • Page 926 TRANSMISSION AND TRANSFER CASE 21 - 191 SPECIAL TOOLS (Continued) Installer, Seal—7884 Remover—L-4454 Cup—8148 Installer, Pump Housing Seal—7888...

  • Page 928: Tires And Wheels

    TIRES AND WHEELS 22 - 1 TIRES AND WHEELS CONTENTS page page TIRES ........1 WHEELS .

  • Page 929: Description And Operation

    22 - 2 TIRES AND WHEELS DESCRIPTION AND OPERATION (Continued) TIRE INFLATION PRESSURES Under inflation will cause rapid shoulder wear, tire flexing, and possible tire failure (Fig. 2). Fig. 2 Under Inflation Wear Over inflation will cause rapid center wear and loss of the tire’s ability to cushion shocks (Fig.

  • Page 930: Tire Pressure For High Speed Operation

    TIRES AND WHEELS 22 - 3 DESCRIPTION AND OPERATION (Continued) pressure decreases as the ambient temperature travel, interference with vehicle components may drops. Check tire pressure frequently when ambient cause tire damage. temperature varies widely. WARNING: FAILURE TO EQUIP THE VEHICLE WITH Tire inflation pressures are cold inflation pressure.

  • Page 931: Service Procedures

    22 - 4 TIRES AND WHEELS DIAGNOSIS AND TESTING (Continued) Fig. 5 Tire Wear Patterns TIRE NOISE OR VIBRATION Radial-ply tires are sensitive to force impulses caused by improper mounting, vibration, wheel defects, or possibly tire imbalance. To find out if tires are causing the noise or vibra- tion, drive the vehicle over a smooth road at varying speeds.

  • Page 932: Repairing Leaks

    TIRES AND WHEELS 22 - 5 SERVICE PROCEDURES (Continued) Fig. 7 Dial Indicator Fig. 9 Remount Tire 180 Degrees Fig. 8 First Measurement On Tire (a) If the high spot is within 101.6 mm (4.0 in.) of the first spot and is still excessive, replace the tire.

  • Page 933: Cleaning And Inspection

    22 - 6 TIRES AND WHEELS SERVICE PROCEDURES (Continued) Install wheel on vehicle, and tighten to proper CLEANING AND INSPECTION torque specification. CLEANING TIRES Remove protective coating on tires before delivery of vehicle. This coating may cause deterioration of tires. To remove the protective coating applying warm water and let it soak for a few minutes.

  • Page 934: Vehicle Safety Certification Label

    TIRES AND WHEELS 22 - 7 WHEELS INDEX page page DESCRIPTION AND OPERATION SERVICE PROCEDURES WHEEL ....... . 7 TIRE AND WHEEL BALANCE .
  • Page 935 22 - 8 TIRES AND WHEELS DIAGNOSIS AND TESTING (Continued) Fig. 3 Radial Runout Fig. 2 Checking Tire/Wheel/Hub Runout Sometimes radial runout can be reduced. Relocate the wheel and tire assembly on the mounting studs (See Method 1). If this does not reduce runout to an acceptable level, the tire can be rotated on the wheel.
  • Page 936 TIRES AND WHEELS 22 - 9 SERVICE PROCEDURES (Continued) WARNING: NEVER USE OIL OR GREASE ON Original equipment wheels are available through STUDS OR NUTS. INSTALLING WHEELS WITHOUT your dealer. Replacement wheels from any other source should be equivalent in: GOOD METAL-TO-METAL CONTACT OR USING •...
  • Page 937 22 - 10 TIRES AND WHEELS SERVICE PROCEDURES (Continued) For static balancing, find location of heavy spot For dynamic balancing, the balancing equipment is causing the imbalance. Counter balance wheel designed to locate the amount of weight to be applied directly opposite the heavy spot.

  • Page 938: General Service Information

    BODY 23 - 1 BODY CONTENTS page page BODY COMPONENT SERVICE ....11 SEATS ........8 GENERAL SERVICE INFORMATION .

  • Page 939: Vehicle Safety Certification Label

    23 - 2 BODY PAINT INDEX page page GENERAL INFORMATION PAINT CODE ......2 AFTERMARKET PAINT REPAIR PRODUCTS .
  • Page 940 BODY 23 - 3 GENERAL INFORMATION (Continued) AFTERMARKET PAINT REPAIR PRODUCTS EXTERIOR COLOR CHRY AKZO EXTERIOR S-W** CODE DuPONT NOBEL ICI** COLOR M-S** SIKKENS Flame Red 4679 B9326 46916 CHA93:PR4 RNN6B Clear Coat Chili Pepper 5361 B9823 54470 CHA98:VEA HMT3B Medium Fern 4969 B9524...

  • Page 941: Vehicle Safety Certification Label

    23 - 4 BODY GENERAL INFORMATION (Continued) NOTE: *Herberts Standox, Spies Hecker, and BASF (9) Apply the hardener/resin mixture to both sides use the Chrysler paint code as listed on the Body of the fiberglass cloth. (10) Place the fiberglass cloth over the repair sur- Code Plate and the Vehicle Safety Certification label.
  • Page 942 BODY 23 - 5 STATIONARY GLASS INDEX page page GENERAL INFORMATION WINDSHIELD ......5 SAFETY PRECAUTIONS .
  • Page 943 23 - 6 BODY REMOVAL AND INSTALLATION (Continued) (6) Clean inside of windshield with ammonia based glass cleaner and lint-free cloth. (7) Apply molding to perimeter of windshield. The butt weld of the molding should be centered at the bottom edge of the windshield. (8) Apply Glass Prep adhesion promoter 25 mm (1 in.) wide around perimeter of windshield and wipe with clean/dry lint-free cloth until no streaks are vis-...
  • Page 944 BODY 23 - 7 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Trim the urethane from the quarter glass open- ing fence. Leave a 3 mm (0.1 in.) level base of ure- thane on the quarter glass opening fence. (2) Place replacement quarter glass into quarter glass opening and position glass in the center of the opening against fence.
  • Page 945 23 - 8 BODY SEATS INDEX page page REMOVAL AND INSTALLATION REAR SEAT CUSHION COVER ... . . 10 BUCKET SEAT CUSHION COVER ... . 9 REAR SEATBACK .
  • Page 946 BODY 23 - 9 REMOVAL AND INSTALLATION (Continued) (7) Separate cover from seatback. BUCKET SEAT CUSHION COVER REMOVAL (1) Remove seat. (2) Remove seatback. (3) Disengage inboard J-strap. (4) Disengage front J-strap. (5) Roll cover up to access hog rings. (6) Disengage inboard, outboard and front hog rings.
  • Page 947 23 - 10 BODY REMOVAL AND INSTALLATION (Continued) (2) Roll the seatback cover downward over the cushion. (3) Install the seatback frame into the cushion/ cover. (4) Engage the seatback cover zipper. (5) Engage the hook and loop fasteners at the seat- back lower corners.
  • Page 948 BODY 23 - 11 BODY COMPONENT SERVICE INDEX page page SERVICE PROCEDURES HOOD ....... . 12 BODY LUBRICATION .
  • Page 949 23 - 12 BODY (8) Remove the bolts attaching the fenders to the SERVICE PROCEDURES grille panel. (9) Remove the bolt attaching the grille to the BODY LUBRICATION frame mount. All mechanisms and linkages should be lubricated (10) Separate the grille from the vehicle. when necessary.
  • Page 950 BODY 23 - 13 REMOVAL AND INSTALLATION (Continued) Fig. 2 Hood Components (6) Remove the screws attaching the hood to the (5) Remove the screws attaching the hinge to the hinge and remove the hood (Fig. 2). hood (Fig. 2). (7) If the hood must be replaced, remove and (6) Separate the hinge from the hood.
  • Page 951 23 - 14 BODY REMOVAL AND INSTALLATION (Continued) Fig. 3 Hood Safety Latch Fig. 5 Cowl Grille And Screen COWL WEATHERSTRIP rectly and in good condition. Misaligned or dam- aged seals may allow water to enter the HEVAC. REMOVAL (1) Position the cowl screen and grille on the cowl. (1) Carefully separate the weatherstrip from the (2) Install the screws that attach the grille and cowl flange (Fig.
  • Page 952 BODY 23 - 15 REMOVAL AND INSTALLATION (Continued) Fig. 7 Windshield Frame Fig. 8 Windshield Frame Weatherstrip INSTALLATION LOWER FRAME WEATHERSTRIP REMOVAL (1) Position the windshield frame on the vehicle. The lower windshield frame weatherstrip can be (2) Install the torx screws attaching the wind- removed with the frame tilted forward to the full hor- shield hinge to the windshield frame.
  • Page 953 23 - 16 BODY REMOVAL AND INSTALLATION (Continued) dure in this group for windshield frame lowering information. (1) Remove door. (2) Remove the bolts attaching the hinge to the cowl (Fig. 9). (3) Remove the bolts attaching the hinge to the windshield frame.
  • Page 954 BODY 23 - 17 REMOVAL AND INSTALLATION (Continued) SIDE VIEW MIRROR FRONT FENDER REMOVAL RIGHT FENDER REMOVAL (1) Remove the screws attaching the mirror to the (1) Disconnect and remove the battery. door hinge (Fig. 11). (2) Remove the air cleaner housing. (2) Remove the mirror from the door hinge.
  • Page 955 23 - 18 BODY REMOVAL AND INSTALLATION (Continued) Fig. 12 FENDER FLARES LEFT FENDER REMOVAL (1) Disconnect the negative terminal on the bat- tery. (2) Remove the windshield washer reservoir. (3) Disengage horn wire connectors. (4) Remove horns. (5) Remove EVAP canister. (6) Remove the bolts attaching the ABS Hydraulic Control Unit (HCU) to the support tray.
  • Page 956 BODY 23 - 19 REMOVAL AND INSTALLATION (Continued) Fig. 14 Front Fender (3) Position the front end lighting wire harness into the retainers on the fender. Engage the retainers to secure. (4) Install the bolts attaching the fender to the HCU tray reinforcement bracket.
  • Page 957 23 - 20 BODY REMOVAL AND INSTALLATION (Continued) SIDE STEP REMOVAL (1) Remove the bolts that attach the side step to the frame (Fig. 16). (2) Separate the side step from the frame. Fig. 17 Full Door Trim Panel Fig. 16 Side Step (2) Disconnect the door restraint strap from the INSTALLATION pin (Fig.
  • Page 958 BODY 23 - 21 REMOVAL AND INSTALLATION (Continued) (2) Mark the outline of the existing hinge on the (3) Remove the grab handle support bracket (Fig. body and the door with a wax pencil for installation 20). alignment reference. (4) Peel back the waterdam from the door inner (3) Remove the nut from the upper hinge pin (Fig.
  • Page 959 23 - 22 BODY REMOVAL AND INSTALLATION (Continued) (4) Connect lock cylinder to latch rod. (5) Secure the waterdam to the door. (6) Install trim panel. FULL DOOR LATCH REMOVAL (1) Remove trim panel. (2) Roll window to full upward position. (3) Disconnect the lock cylinder to latch rod (Fig.
  • Page 960 BODY 23 - 23 REMOVAL AND INSTALLATION (Continued) Fig. 24 Full Door Latch Fig. 26 Inside Handle Actuator FULL DOOR LATCH STRIKER INSTALLATION INSTALLATION REMOVAL (1) Connect the latch rods to the handle. (1) Remove the screws attaching the striker to the (2) Position handle and seal in door.
  • Page 961 23 - 24 BODY REMOVAL AND INSTALLATION (Continued) Fig. 27 Door Sail Screws Fig. 29 Full Door Outer Belt Seal (2) Using a trim stick, carefully pry the glass run channel weatherstrip from the window opening frame. (3) Remove the door glass. (4) Grasp the glass run channel weatherstrip in the door (Fig.
  • Page 962 BODY 23 - 25 REMOVAL AND INSTALLATION (Continued) FULL DOOR WEATHERSTRIP (4) Remove the bolts attaching the regulator to the door inner panel. The upper portion of the weatherstrip is seated (5) Lift the regulator upward to free it from the into a channel around the window opening frame.
  • Page 963 23 - 26 BODY REMOVAL AND INSTALLATION (Continued) (3) Remove the screws attaching trim panel to (2) Disconnect the outside handle to latch rod (Fig. door. 35). (4) Remove push-in fasteners attaching trim panel (3) Remove screws attaching the outside handle to to door with special tool C-4829.
  • Page 964 BODY 23 - 27 REMOVAL AND INSTALLATION (Continued) HALF DOOR LATCH (4) Position the door weatherstrip in place, apply adhesive as necessary. (5) Connect the outside handle to latch rod. REMOVAL (6) Connect the lock knob to latch rod. (1) Remove trim panel. (7) Connect the lock cylinder to latch rod (Fig.
  • Page 965 23 - 28 BODY REMOVAL AND INSTALLATION (Continued) (3) Position the seal on the door and press it into place. (4) Install the weatherstrip in the weatherstrip channel ensuring that the weatherstrip is fully engaged in the weatherstrip channel. (5) Install window retaining sleeve. (6) Install trim panel.
  • Page 966 BODY 23 - 29 REMOVAL AND INSTALLATION (Continued) Fig. 42 Hard Top Latch Fig. 45 Rear Washer Fluid Tube (5) Connect the rear washer fluid hose. (6) Engage the latches at windshield frame. HARD TOP AIR EXHAUSTER The hard top air exhauster fits very tightly into the hard top and generally cannot be removed with- out being damaged.
  • Page 967 23 - 30 BODY REMOVAL AND INSTALLATION (Continued) (8) Remove the screws attaching the roof bows to (10) Engage the retainers attaching the rear win- the pivot bracket (Fig. 47). dow to the body. (9) Lift up bows at pivot bracket to disengage from (11) Close latch at windshield frame.
  • Page 968 BODY 23 - 31 REMOVAL AND INSTALLATION (Continued) Fig. 48 Soft Top Fig. 49 Hard/Soft Top Latch Fig. 50 Door Opening Frame (2) Position the door opening frame on the side FRONT SHOULDER/LAP BELT AND RETRACTOR support bar and install the knobs. REMOVAL (3) Raise and secure the top.
  • Page 969 23 - 32 BODY REMOVAL AND INSTALLATION (Continued) Fig. 51 Front Retractor Fig. 53 Seat Belt Buckle (2) Engage seat belt harness connector (driver’s seat only). REAR SHOULDER/LAP BELT AND BUCKLE WARNING: INSPECT SHOULDER BELT, RETRACTOR AND BUCKLE. REPLACE THE BELT OR BUCKLE THAT IS EITHER CUT, FRAYED, TORN OR DAMAGED.
  • Page 970 BODY 23 - 33 REMOVAL AND INSTALLATION (Continued) Fig. 54 Turning Loop Cover Fig. 56 Rear Belt Assembly Fig. 55 Turning Loop (4) Position the belt anchor on the wheelhouse and install the bolt. Tighten the bolt to 47 N·m (35 ft. lbs.) torque.
  • Page 971 23 - 34 BODY REMOVAL AND INSTALLATION (Continued) (4) Using a trim stick, pry up shift boot and remove (manual trans only). (5) Remove the trim disc from the bottom of the cup holder. (6) Remove the bolts attaching the console to the floor pan (Fig.
  • Page 972 BODY 23 - 35 REMOVAL AND INSTALLATION (Continued) (6) Remove the bolts attaching the console to the floor pan (Fig. 61). (7) Shift transfer case to four low position. (8) Engage parking brake. (9) Lift the console upward and rotate to remove through the passenger door.
  • Page 973 23 - 36 BODY REMOVAL AND INSTALLATION (Continued) Fig. 64 Rear Seat (2) Pull on the rear seat latch to disengage the rear seat from the striker. (3) Lift the rear seat to the forward tumble posi- tion. (4) Remove the hitch pins from the seat frame pivot pins.
  • Page 974 BODY 23 - 37 REMOVAL AND INSTALLATION (Continued) WHEELHOUSE CARPET REMOVAL (1) Position the rear seat in the full forward posi- tion. (2) If equipped, remove the Add-A-trunk. (3) Grasp wheelhouse carpet and remove from vehicle (Fig. 67). INSTALLATION (1) Position wheelhouse carpet in vehicle and adjust as necessary.
  • Page 975 23 - 38 BODY REMOVAL AND INSTALLATION (Continued) Fig. 67 Vehicle Carpet (6) Install the bolts attaching the seatbelt anchors to the wheelhouse. (7) Install the bolts attaching the directional cross bars to the wheelhouse and install the wheelhouse carpet. Tighten the bolts to 40 N·m (30 ft. lbs.) torque.
  • Page 976 BODY 23 - 39 REMOVAL AND INSTALLATION (Continued) Fig. 69 Sport Bar REAR VIEW MIRROR CAUTION: Do over-tighten setscrew because glass chipping and/or breakage could result. REMOVAL (1) Loosen the mirror set screw. (2) Tighten the mirror setscrew to 1 N·m (9 in. (2) Slide the mirror up and off the support button lbs.) torque.
  • Page 977 23 - 40 BODY REMOVAL AND INSTALLATION (Continued) erator to dry for one minute. Do not touch the glass WHEELHOUSE SPLASH SHIELD contact surface after the accelerator has been applied. REMOVAL (6) Install the bracket according to the following (1) Remove the plastic push pins that attach the instructions: splash shield to the wheelhouse (Fig.
  • Page 978 BODY 23 - 41 REMOVAL AND INSTALLATION (Continued) ATTEMPT TO DISASSEMBLE OR REPAIR THE SUP- PORT RODS. (3) Open the tailgate and liftgate. (4) Remove support rod cylinders. (5) Remove the bolts attaching the liftgate hinge to the hardtop (Fig. 76). (6) Separate the liftgate glass from the hard top.
  • Page 979 23 - 42 BODY REMOVAL AND INSTALLATION (Continued) LIFTGATE GLASS HINGE REMOVAL (1) Open tailgate. (2) Open and support liftgate glass. (3) Remove wiper motor cover (right hinge only). (4) Remove the nut attaching the liftgate hinge to the liftgate glass. (5) Mark the position of the hinge in the top and remove the bolts attaching the hinge to the top (Fig.
  • Page 980 BODY 23 - 43 REMOVAL AND INSTALLATION (Continued) REMOVAL (1) Using a wax pencil, mark the position of the hinge on the body. (2) Remove the screws attaching the hinge to the body and tailgate (Fig. 82). (3) Separate the hinge from the tailgate. Fig.
  • Page 981 23 - 44 BODY REMOVAL AND INSTALLATION (Continued) (2) Install the screw attaching latch to tailgate. Do not tighten screw. (3) Connect the lock cylinder to latch rod. (4) Connect the outside handle to latch rod. (5) Install the latch trim cover. Tighten all screws. TAILGATE LATCH STRIKER REMOVAL (1) Remove the striker from the bracket with a...
  • Page 982 BODY 23 - 45 REMOVAL AND INSTALLATION (Continued) (a) Clean the channel contact surface on the tail- ADJUSTMENTS gate with isopropyl alcohol, or equivalent. (b) Peel the paper backing from the weatherstrip HOOD ADJUSTMENT channel. The hood hinge screw holes are oversized to facili- (c) Position weatherstrip channel to the tailgate tate hood adjustment movement.
  • Page 983 23 - 46 BODY SPECIFICATIONS BODY LUBRICANTS COMPONENT SERVICE INTERVAL LUBRICANT Door Latches As Required Multi-Purpose Grease NLGI GC-LB (Water Resistant) (1) Hood Latch, Release Mechanism & As Required Multi-Purpose Grease NLGI GC-LB 2 Safety Latch (When Performing Other EP (2) Underhood Service) Hood Hinges As Required...
  • Page 984 BODY 23 - 47 SPECIFICATIONS (Continued) WELD LOCATIONS DASH, COWL AND PLENUM...
  • Page 985 23 - 48 BODY SPECIFICATIONS (Continued) DASH, COWL AND PLENUM...
  • Page 986 BODY 23 - 49 SPECIFICATIONS (Continued) DASH, COWL AND PLENUM...
  • Page 987 23 - 50 BODY SPECIFICATIONS (Continued) DASH, COWL AND PLENUM...
  • Page 988 BODY 23 - 51 SPECIFICATIONS (Continued) DASH, COWL AND PLENUM...
  • Page 989 23 - 52 BODY SPECIFICATIONS (Continued) DASH, COWL AND PLENUM SUPPORTS AND REINFORCEMENTS...
  • Page 990 BODY 23 - 53 SPECIFICATIONS (Continued) DASH, COWL AND PLENUM SUPPORTS AND REINFORCEMENTS...
  • Page 991 23 - 54 BODY SPECIFICATIONS (Continued) DASH, COWL AND PLENUM SUPPORTS AND REINFORCEMENTS...
  • Page 992 BODY 23 - 55 SPECIFICATIONS (Continued) DASH, COWL AND PLENUM SUPPORTS AND REINFORCEMENTS...
  • Page 993 23 - 56 BODY SPECIFICATIONS (Continued) FRONT FLOOR, STRAINER, REINFORCEMENT AND COWL SIDE LOWER...
  • Page 994 BODY 23 - 57 SPECIFICATIONS (Continued) FRONT FLOOR, STRAINER, REINFORCEMENT AND COWL SIDE LOWER...
  • Page 995 23 - 58 BODY SPECIFICATIONS (Continued) FRONT FLOOR, STRAINER, REINFORCEMENT AND COWL SIDE LOWER...
  • Page 996 BODY 23 - 59 SPECIFICATIONS (Continued) FRONT FLOOR, STRAINER, REINFORCEMENT AND COWL SIDE LOWER...
  • Page 997 23 - 60 BODY SPECIFICATIONS (Continued) SIDE APERTURE...
  • Page 998 BODY 23 - 61 SPECIFICATIONS (Continued) SIDE APERTURE...
  • Page 999 23 - 62 BODY SPECIFICATIONS (Continued) SIDE APERTURE...
  • Page 1000 BODY 23 - 63 SPECIFICATIONS (Continued) SIDE APERTURE...
  • Page 1001 23 - 64 BODY SPECIFICATIONS (Continued) SIDE APERTURE...
  • Page 1002 BODY 23 - 65 SPECIFICATIONS (Continued) WHEELHOUSE...
  • Page 1003 23 - 66 BODY SPECIFICATIONS (Continued) WHEELHOUSE...
  • Page 1004 BODY 23 - 67 SPECIFICATIONS (Continued) WHEELHOUSE...
  • Page 1005 23 - 68 BODY SPECIFICATIONS (Continued) REAR FLOOR PAN AND REINFORCEMENTS...
  • Page 1006 BODY 23 - 69 SPECIFICATIONS (Continued) REAR FLOOR PAN AND REINFORCEMENTS...
  • Page 1007 23 - 70 BODY SPECIFICATIONS (Continued) REAR FLOOR PAN AND REINFORCEMENTS...
  • Page 1008 BODY 23 - 71 SPECIFICATIONS (Continued) DOOR OUTER PANELS...

Table of Contents