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1979 J-20 Truck 46
Jeep 1979 J-20 Truck 46 Manuals
Manuals and User Guides for Jeep 1979 J-20 Truck 46. We have
1
Jeep 1979 J-20 Truck 46 manual available for free PDF download: Technical & Service Manual
Jeep 1979 J-20 Truck 46 Technical & Service Manual (1038 pages)
Brand:
Jeep
| Category:
Automobile
| Size: 62.96 MB
Table of Contents
How to Use this Manual
4
Vehicle Identification Plate
9
Vehicle Identification Number (VIN)
9
Keys and Locks
10
Paint Option Numbers
10
Sefety Certification Sticker
10
Towing
11
Conversion of English and Metric Measures
13
Power Train Combinations
15
General Dimensions
16
Decimal Equivalents
17
Maintenance
20
Fuel Requirements
20
Heavy-Duty Operation
20
Maintenance Schedule
21
Description of Services - Engine Components
25
Automatic Transmission (Fluid Check)
25
Battery Maintenance
25
Brake Master Cylinder Maintenance
26
Coolant
26
Drive Belts Care
26
Oil Change
26
Oil Filter
27
Power Steeing Pump Maintenance
27
Tune-Up
27
Chassis Components
28
Axle Differentials (Front and Rear)
28
Bearings, Front Wheel
28
Body Lubrication; Brake and Chassis Inspection
28
Brakes Maintenance
29
Master Cylinder Maintenance
30
Front Brake Linings
30
Rear Brake Linings
30
Clutch Lever and Linkage Maintenance
31
Parking Brake
31
Tire Condition
31
Manual Transmission Clutch Inspection and Adjustment
31
Exhaust System Inspection
32
Propeller Shafts (Front and Rear)
32
Transmission Maintenance
33
Quadra-Trac Fluid Change
33
Automatic Transmissin Fluid Changes
33
Unscheduled Maintenance
34
Manual Transmission Fluid Change
34
Catalytic Converter
34
Fluid Capacities
34
Recommended Fluids and Lubricants
35
Power Plant
36
Emission Components
38
Power Plant Diagnosis
39
Power Plant Diagnosis with Scope Analyzer
48
Compression Test
48
Cylinder Leakage Test
48
Scope Diagnosis Pattern - Ignition Primary
49
Blown Cylinder Head Gasket Diagnosis
50
Cylinder Leakage Test Diagnosis
50
Intake Leak Diagnosis
50
Power Plant Tune-Up
51
Oil Filler Cap
51
Drive Belts
51
Vacuum Fittings, Hoses and Lines
51
Spark Plug Condition
52
Spark Plug Wires
53
Initial Ignition Timing
54
Magnetic Timing Probe
54
Fuel Systems Maintenance
55
Distributor Advance Mechanism
55
Fuel Filter
55
Engine Idle Speed and Mixture Setting Procedures
56
Choke Linkage
57
PCV Air Inlet Filter
57
Fuel Tank Vapor Emission Control System
57
Exhaust System Maintenance
58
Exhaust Manifold Heat Valve
58
Tune-Up Specifications - On-Vehicle
58
Distributor Curves - On-Vehicle
59
Distributor Wiring Sequence and Firing Order
61
Engines
62
Short Engine Assembly (Short Block)
63
Six-Cylinder Engine Assembly View
63
Engine Build Date Location
63
Engine Mounting
64
Engine Holding Fixture
64
Engine Build Date Code
64
Oversize or Undersize Components
64
Engine Removal
65
Engine Installation
65
Valve Train
65
Rocker Arm Assembly
66
Valves Removal, Cleaning and Inspection
66
Valve Refacing
66
Valve Seat Refacing
66
Valve Stem Oil Deflector Replacement
67
Valve Stem-To-Guide Clearance
67
Valve Guides
67
Valve Spring and Oil Deflector Removal
68
Valve Spring Tension Test
68
Camshaft and Bearings
69
Oil Deflector and Valve Spring Installation
69
Measuring Cam Lobe Lift
69
Checking Valve Timing
69
Camshaft Removal
70
Camshaft Inspection
70
Camshaft Installation
70
Camshaft Bearing Replacement
70
Hydraulic Valve Tappets
71
Hydraulic Tappet Leak-Down Test
72
Timing Case Cover
73
Oil Pan Front Seal Installation
73
Timing Case Cover Alignment
73
Timing Case Cover Oil Seal Replacement (Cover Not Removed)
73
Timing Chain
74
Intake and Exhaust Manifolds
75
Intake Manifold Replacement
76
Exhaust Manifold Replacement
76
Cylinder Head Cover
77
Cylinder Head
77
Lubrication System
78
Cylinder Head Torque Sequence
78
Oil Filter and Oil Pump
80
Oil Pan Removal and Installation
82
Connecting Rod and Piston Assembly
83
Connecting Rods
83
Connecting Rod Bearing Fitting Chart
84
Measuring Connecting Rod Bearing Clearance
85
Pistons
86
Piston Fitting
86
Piston Rings
86
Piston Pins
87
Crankshaft End Play Measurement
89
Crankshaft Main Bearings
89
Rear Main Bearing Oil Seal (Crankshaft)
92
Cylinder Block Disassembly
93
Flywheel and Starter Ring Gear Assembly
93
Ring Gear Replacement (Manual Transmission)
93
Vibration Damper Removal
93
Cylinder Bore Reconditioning
94
Measuring Cylinder Bore
94
Resurfacing Cylinder Bore
94
Six-Cylinder Engine Specifications
95
Eight-Cylinder Engine
97
Short Engine Assembly (Short Block) (8-Cylinder)
99
Engine Mounting (8-Cylinder)
99
Engine Removal (8-Cylinder)
99
Engine Installation (8-Cylinder)
100
Valve Train (8-Cylinder)
101
Rocker Arm Assembly (8-Cylinder)
101
Valves (8-Cylinder)
101
Valve Refacing (8-Cylinder)
102
Valve Stem Oil Deflector Replacement (8-Cylinder)
102
Valve Guides (8-Cylinder)
102
Valve Stem-To-Guide Clearance (8-Cylinder)
103
Valve Springs (8-Cylinder)
103
Camshaft and Bearings (8-Cylinder)
104
Cam Lobe Lift Measurement
104
Valve Timing
105
Camshaft Removal (8-Cylinder)
105
Camshaft Inspection (8-Cylinder)
105
Hydraulic Valve Tappet
106
Camshaft Installation (8-Cylinder)
106
Hydraulic Tappet Leak-Down Test
107
Timing Case Cover (8-Cylinder)
108
Timing Chain (8-Cylinder)
110
Oil Seal Replacement
110
Intake Manifold (8-Cylinder)
111
Cylinder Head and Cover
112
Exhaust Manifold (8-Cylinder)
112
Lubrication System (8-Cylinder)
114
Oil Filter (8-Cylinder)
114
Oil Pump
114
Oil Pressure Relief Valve
114
Gear End Clearance Measurement
116
Gear-To-Body Clearance
117
Connecting Rod and Piston Assembly (8-Cylinder)
118
Connecting Rods (8-Cylinder)
119
Pistons (8-Cylinder)
121
Piston Fitting (8-Cylinder)
122
Piston Rings (8-Cylinder)
122
Piston Pins (8-Cylinder)
124
Crankshaft (8-Cylinder)
125
Crankshaft Main Bearings (8-Cylinder)
125
Rear Main Bearing Oil Seal
127
Vibration Damper
128
Cylinder Block Disassembly (8-Cylinder)
129
Flywheel and Starter Ring Gear Assembly (8-Cylinder)
129
Ring Gear Replacement - Manual Transmission (Flywheel Removed)
129
Cylinder Bore Reconditioning (8-Cylinder)
129
Eight-Cylinder Engine Specifications
131
Cooling Systems
136
Water Pump
137
Thermostat
137
Radiator Pressure Cap
137
Fan
137
Coolant Recovery System
138
Temperature Gauge
138
Cooling System Operation
139
Engine Block Heater
139
Heater Core
139
Spark Coolant Temperature Override (CTO) Switch
139
Cooling System Diagnosis
140
Coolant Recovery Operation
140
CTO Operation
140
Low Engine Temperature Diagnosis Guide
144
Engine Overheating Diagnosis Guide
144
Cooling System Troubleshooting
146
Cooling System Leakage
146
Combustion Leakage (Without Pressure Tester)
146
Oil Cooler Leakage
147
Radiator Pressure Cap Test
147
Thermostat Test
147
Water Pump Tests
148
Tempatrol Fan Test
148
Drive Belts Adjustment
149
Fan and Alternator Belt Adjustment
149
Air Conditioning Belt Adjustment
150
Power Steering Drive Belt
150
Hoses (Cooling System)
151
Shroud Position
151
Coolant Level
151
Coolant Draining and Filling
151
Engine Block Heater Installation
152
Bleeding Air from Cooling System
152
Engine Flushing
152
Core Plug Replacement
152
Fan Replacement
153
Water Pump Pulley Replacement
153
Coolant Recovery Bottle Replacement
153
Radiator
153
Radiator Replacement
154
Thermostat Replacement
154
Reverse Flushing
154
Oil Cooler Repairs
154
Water Pump Removal and Installation
155
Cooling System Specifications
156
Engine Drive Belt Tension
158
Engine Drive Belt Arrangement
158
Batteries
162
Reserve Capacity Rating
162
Battery Coding
162
Battery Replacement
162
Battery Installation
163
Battery Charging
164
Frozen Electrolyte
164
Battery Storage
164
Discharge/Charge Chemical Action
164
Dry Charge Battery
165
Slow Charge
165
Fast Charge
165
Booster Charging
165
Battery Testing
166
Hydrometer Test
166
Heavy Load Test
167
Battery Diagnosis and Repair Chart
168
Engine will Not Crank
168
Battery Specifications
170
Charging System
172
Alternator
172
Voltage Regulator
173
Charging System Operation
173
Charging System Troubleshooting
174
Alternator Noise
174
Alternator Leakage
174
Charging System Diagnosis and Repair Simplification Chart
175
Battery Undercharged
175
Battery Overcharged (Uses too Much Water)
177
Rotor Shoft-To-Ground Test
178
Rotor Open Test
178
Rotor Internal Short Test
178
Stator Short-To-Ground Test
179
Stator Continuity Test
179
Stator Internal Short Circuit Test
179
Diode Trio Short Circuit Test
179
Alternator Replacement
180
Rectifier Bridge Test
180
Alternator Overhaul
181
Alternator Cleaning and Inspection
182
Alternator Assembly
183
Drive Belt Adjustment
184
Charging System Specifications
185
Starting System
186
Starter Motor
186
Starting System Troubleshooting
187
Starter Solenoid
187
Neutral Safety Switch
187
Starter System Circuits
187
Starter System Schematic
188
Starter Cable and Ground Cable Tests
190
Current Draw Test
190
Neutral Safety Switch Test
190
Starter Voltage Drop Test Diagnosis and Repair Charts
191
Starter Motor Off-Vehicle Testing
193
No-Load Test
193
Hold-In Coil Resistance Test
193
Solenoid Point Connection Test
193
Insulated Brush Connection Test
194
Terminal-To-Brush Continuity Test
194
Terminal Bracket Insulation Test
194
Starter Motor Replacement
195
Armature Tests
195
Starter Motor Overhaul
196
Starter Motor Cleaning and Inspection
196
Field Coil Replacement
197
Solenoid Contact Assembly Replacement
197
Bushing Replacement
198
Drive Assembly Replacement
198
Starter Motor Assembly
198
Neutral Safety Switch Replacement
199
Starter Motor Specifications
199
Ignition System
200
Control Unit
200
Ignition Coil
201
Resistance Wire
201
Distributor
201
Ignition System Operation
202
Ignition System Troubleshooting
202
Spark Advance
202
SSI System Schematic
203
Ignition System Service Diagnosis
204
SSI System Diagnosis and Repair Chart
206
Coil Test
209
Sensor Check and Control Unit Check
210
Ignition Feed to Electronic Control Unit
212
Engine Spark Knock (Ping) Diagnosis
213
Distributor Advance Tests
213
Coil Tests
213
Distributor Replacement
214
Distributor Component Replacement
215
Trigger Wheel And/Or Sensor
215
Vacuum Unit Removal and Installation
216
Rotor
216
Spark Control Systems
217
Distributor and Coil Specifications
217
Spark Coolant Temperature Override (CTO) Systems
218
Spark Coolant Temperature Override Dual Range (Dual Range CTO)
218
Non-Linear Vacuum Regulator (NLRV) Valve
219
Spark Coolant Temperature Override - Heavy Duty Cooling
219
Spark CTO Replacement
219
Non-Linear Vacuum Regulator Valve Test and Replacement
220
Cruise Command
222
Governor Assembly
223
Solenoid and Valve Assembly
223
Slide Switch on (Cruise Command)
224
Pushbutton Depressed - Setting Speed
224
Pushbutton Released - Maintaining Speed
224
Coupling Coil and Centering Spring Assembly
224
Brake Release
225
Current Flow - Slide Switch on Diagram
225
Cruise Command Testing
226
Resume Switch Operation
226
Control Switch Continuity Test
226
Circuitry Tests (Cruise Command)
227
Current Flow - Pushbutton Released - Maintaining Speed
227
Current Flow - Brake Release
228
Current Flow - Resume Slide Switch Operation
229
Cruise Command Service Diagnosis
230
Cruise Command Adjustments
232
Release Circuit Test
232
Automatic Speed Control Relay Test
232
Bellows Chain Linkage Adjustment
232
Centering Spring Adjustment
233
Cruise Command Schematic
233
Regulator Replacement
234
Bellows Replacement
234
Bellows Chain Replacement
234
Control Switch Replacement (Cruise Command)
234
Fuel Systems
236
Air Cleaner
236
Fuel Filters
237
Fuel Tank Replacement
237
Fuel Tank Sending Unit
238
Fuel Tank Filler Neck
238
Fuel Tank and Vent Lines Diagrams
239
Fuel Vapor Control System
240
Fuel Tank Filler Cap
240
Charcoal Canister
240
Liquid Check Valve
240
Fuel Return System
241
Rollover Check Valve
241
Carburetor Mechanical Bowl Vent
241
Fuel Pump
242
Fuel Pump Pressure Test
243
Fuel Pump Capacity (Volume) Test
243
Fuel Pump Vacuum Tests
243
Carburetor - BBD-2 Venturi
244
Fuel Pump Replacement
244
Fuel Pump Specifications
244
Carburetor Circuits
245
Power Enrichment Circuit
246
Pump Circuit
246
Choke Circuit
246
Carburetor Replacement
247
Carburetor Overhaul
247
Carburetor Parts Identification
248
Carburetor Disassembly
249
Carburetor Cleaning and Inspection
250
Carburetor Assembly
251
Accelerator Pump Check
251
Float Level Adjustment
252
Vacuum Piston Gap Adjustment
252
Vacuum Piston Adjustment
252
Accelerator Pump Adjustment
252
Initial Choke Valve Clearance Adjustment
253
Fast Idle Cam Position Adjustment
253
Choke Mechanical Service
254
Choke Unloader Adjustment
254
Automatic Choke Adjustment
254
Carburetor Specifications (BBD)
254
Carburetor - Model 2100-2 Venturi
255
Float (Fuel Inlet) Circuit (2100-2 Venturi)
256
Idle (Low Speed) Circuit (2100-2 Venturi)
256
Main Metering (High Speed) Circuit (2100-2 Venturi)
257
Power Enrichment Circuit (2100-2 Venturi)
257
Pump Circuit (2100-2 Venturi)
258
Choke Circuit (2100-2 Venturi)
258
Carburetor Replacement (2100-2 Venturi)
259
Carburetor Overhaul (2100-2 Venturi)
259
Carburetor Parts Identification (2100-2 Venturi)
260
Carburetor Disassembly (2100-2 Venturi)
261
Carburetor Cleaning and Inspection (2100-2 Venturi)
262
Carburetor Assembly (2100-2 Venturi)
263
Carburetor Service Adjustment Procedures (2100-2 Venturi)
264
Float Level Adjustment (2100-2 Venturi)
264
Initial Choke Valve Clearance Adjustment (2100-2 Venturi)
265
Fast Idle Cam Linkage Adjustment (2100-2 Venturi)
265
Choke Unloader Adjustment (2100-2 Venturi)
266
Automatic Choke Adjustment (2100-2 Venturi)
266
Accelerating Pump Stroke Adjustment (2100-2 Venturi)
266
Choke Mechanism Service (2100-2 Venturi)
267
Carburetor Specifications (2100-2 Venturi)
267
Fast Idle Speed Adjustment (2100-2 Venturi)
267
Bowl Vent (2100-2 Venturi)
267
Carburetor - Model 2150 Venturi
268
Carburetor Circuits (2150 Venturi)
269
Carburetor Overhaul (2150 Venturi)
269
Initial Choke Valve Clearance Adjustment (2150 Venturi)
270
Carburetor Specifications (2150 Venturi)
270
Vacuum Throttle Modulating (VTM) System
271
Exhaust Gas Recirculation (EGR) System
272
EGR Valve
273
EGR Valve Replacement
274
EGR Valve Maintenance
274
EGR CTO Switch
274
Exhaust Back-Pressure Sensor - Non-Integral
275
EGR CTO Test
275
EGR CTO Switch Replacement
275
Positive Crankcase Ventilation (PCV) System
276
Restrictor Plates
276
Non-Integral Exhaust Back-Pressure Sensor Test
276
PCV Valve Test
277
PCV Air Inlet Filter Maintenance
277
Positive Crankcase Ventilation (PCV) Valve
277
Thermostatically Controlled Air Cleaner (TAC) System
278
TAC System Operation
279
TAC System Testing
279
Thermal Sensor Operation
279
Carburetor Bowl Cooling System
280
Cooling Fan Replacement
280
Timer Replacement
280
Hose Replacement (TAC)
280
Sensor Replacement (TAC)
281
Deflector Replacement (TAC)
281
Vent Replacement (TAC)
281
Carburetor Bowl Cooling System Diagnosis
281
Exhaust Systems
284
Exhaust Manifolds, Mufflers and Pipes
284
Restricted Exhaust System Diagnosis
284
Exhaust System Diagrams
285
Exhaust Manifold Replacement (6-Cylinder)
289
Exhaust Manifold Replacement (8-Cylinder)
290
Heat Valve
290
Muffler Replacement
291
Air Guard System
292
Exhaust Pipe Replacement
292
Tailpipe Replacement
292
Exhaust System Specifications
292
Air Pump Components and Operation
293
Diverter (Bypass) Valve
294
Air Pump Noise Diagnosis
294
Air Pump Replacement
294
Air Injection Manifolds
295
Diverter Test
295
Check Valve Test
295
Catalytic Converter System
296
Catalytic Converter Operation
297
Catalyst Replacement
297
Power Plant Instrumentation
300
Ammeter
300
Constant Voltage Regulator (CVR)
300
Fuel Gauge
301
Tachometer
301
Voltmeter
301
Instrumentation Diagnosis
302
Ammeter Diagnosis
302
Fuel Gauge Diagnosis
302
Oil Pressure Gauge Diagnosis
302
Instrument Cluster Replacement
303
Tachometer Diagnosis
303
Temperature Gauge Diagnosis
303
Gauge Replacement
304
Printed Circuit Replacement
305
Constant Voltage Regulator (CVR) Replacement
305
Diagnosis and Repair Simplification (DARS) Charts
306
Fuel Gauge Not Functioning Properly
307
Gauge Fuse Blown
316
Neither Temperature Gauge nor Furl Gauge Operates
318
Oil Pressure Gauge Not Functioning Properly (CJ)
320
Oil Pressure Gauge Not Functioning Properly
325
Temperature Gauge Not Functioning Properly
331
Power Plant Instrumentation - Circuits and Schematics
339
Chassis
346
Clutch Overview
348
Clutch Service Diagnosis
348
Clutch Chatter
348
Throwout Bearing Application
349
Clutch Assembly View
349
Clutch Slippage or Inadequate Clutch Linkage Free Play
350
Clutch Drag or Inadequate Release
351
Clutch Pedal Pulsation
352
Clutch Related Vibrations
352
Clutch Adjustments
353
Clutch Pedal Free Play Adjustment
353
Clutch Linkage
353
Clutch Noises
353
Clutch Service
355
Clutch Removal and Installation
355
Clutch Linkage Lubrication
355
Driven Plate Service
356
Clutch Cover Service
356
Transmission Front Bearing Cap Service
356
Crankshaft Pilot Bushing Service
356
Clutch Housing Alignment
357
Clutch Cover Release Lever Adjustment
358
Clutch Pedal and Overcenter Spring Replacement
359
Clutch Specifications
361
Manual Transmission
364
Backup Lamp Switch
364
TCS Switch
364
Transmission Lubricant
364
Manual Transmission Service Diagnosis
365
Transmission Removal
366
3-Speed Transmission Disassembly (Model T-150)
367
Transmission Installation
367
Transmission Model T-150 Exploded View
368
Main Shaft Gear Train Disassembly
369
Clutch Shaft Disassembly
370
Transmission Cleaning and Inspection
370
Transmission Assembly (T-150)
370
Shift Control Housing Disassembly and Assembly
374
3-Speed Transmission Model T-15A Disassembly
375
Manual Transmission Specifications
375
Main Shaft Gear Train Disassembly (T-15A)
377
Transmission Cleaning and Inspection (T-15A)
378
Transmission Assembly (T-15A)
379
Shift Control Housing Disassembly
381
Transmission Specifications (T-15A)
382
4-Speed Transmission Disassembly - Model T-18A
383
Main Shaft Gear Train Disassembly (T-18A)
385
Transmission Cleaning and Inspection (T-18A)
385
Transmission Assembly (T-18A)
386
Transmission Case Assembly (T-18A)
388
Shift Control Housing View - Transmission T-18A
389
Shift Control Housing Disassembly and Assembly (T-18A)
390
Transmission Specifications (T-18A)
391
Automatic Transmission
396
Torque Converter
397
Manual Linkage-Vacuum Modulator-Detent Solenoid
397
Hydraulic System Operation
398
Planetary Gear Train
398
Roller Clutches
398
Governor
398
Front Servo
399
Drive Range
399
Rear Servo
399
Detent and Detent Regulator Valves
400
Reverse
400
Accumulator
400
Park-Neutral
400
Automatic Transmission Diagnosis and Test Procedures
401
Automatic Transmission Fluid Level and Condition
402
Automatic Transmission Road Test
403
Hydraulic Pressure Test
404
Control Valve and Governor Test
404
Test Gauge Installation
405
Modulator Test
406
High Line Pressure Check
406
Vacuums Diaphragm Leak Test
406
Plunger Travel and Vacuum Holding Test
406
Converter Housing Leak Diagnosis
407
Plunger Cylinder Concentricity Check
407
Late/Harsh Upshift
408
Slipping (Engine Flares)
411
No Drive/Reverse
413
No Detent Downshift
414
Automatic Transmission Diagnosis Chart
415
Transmission Noisy
415
Drive in Neutral
416
Won't Hold in Park or Won't Release from Park
416
Causes of Oil Leaks (Automatic Transmission)
416
Causes of Burned Clutch Plates
417
Causes of Low Line Pressure
417
Causes of High Line Pressure
418
Causes of Improper Vacuum at Modulator
418
Hydraulic Pressure Test Specifications
418
Control Valve and Governor Test Specifications
419
Shift Speed Chart
419
Automatic Transmisison In-Vehicle Service and Adjustment
420
Manual Linkage Adjustment
420
Neutral Switch Adjustment
421
Pressure Regulator Valve Removal and Installation
421
Detent Solenoid Removal and Installation
422
Control Valve and Oil Filter Removal and Installation
422
Governor Removal and Installation
422
Modulator Removal and Installation
423
Parking Linkage Removal and Installation
423
Automatic Transmission Out-Of Vehicle Service and Overhaul
424
Automatic Transmission Removal
424
Automatic Transmission Installation
425
Automatic Transmission Disassembly
425
Governor-Oil Pan-Oil Filter-Intake Pipe Removal/Installation
426
Detent Roller and Spring-Control Valve-Governor Screen-Governor Pipes
426
Rear Servo Removal
427
Band Adjustment
427
Detent Solenoid-Electrical Connector-Control Valve Spacer-Front Servo
428
Extension Housing - Rear Bearing Removal/Installation
428
Front Unit End Play Measurement
429
Oil Pump-Forward Clutch-Turbine Shaft-Direct Clutch Removal
430
Manual Shaft-Parking Pawl Removal and Installation
431
Front Band-Sun Gear Shaft Removal and Installation
432
Rear Unit End Play Measurement
433
Intermediate Clutch Removal and Installation
433
Center Support-Gear Unit-Rear Band-Center Support Spacer Ring Removal
434
Subassembly Overhaul (Automatic Transmission)
435
Governor Disassembly
437
Governor Cleaning and Inspection
437
Governor Driven Gear Replacement
438
Governor Assembly (Automatic Transmission)
438
Front Servo Inspection
439
Rear Servo-Accumulator Disassembly, Inspection, Assembly
439
Control Valve Disassembly
440
Control Valve Inspection
440
Control Valve Assembly
441
Oil Pump Disassembly and Inspection (Automatic Transmission)
442
Oil Pump Assembly (Automatic Transmission)
443
Forward Clutch Disassembly
444
Forward Clutch Inspection
445
Forward Clutch Assembly
446
Direct Clutch - Intermediate Roller Clutch Disassembly
448
Direct Clutch - Intermediate Roller Clutch Inspection and Assembly
449
Center Support Disassembly, Inspection, Assembly
452
Reaction Carrier-Roller Clutch-Output Carrier
454
Output Shaft Inspection
456
Sun Gear and Shaft Inspection
456
Front and Rear Band Inspection
456
Modulator and Valve Inspection
456
Manual Linkage-Parking Linkage Inspection
457
Transmission Case Inspection
457
Bushing Replacement (Automatic Transmission)
459
Planetary Gear Assembly View
465
Automatic Transmission Assembly
466
Gear Unit and Intermediate Clutch
469
Measuring Rear Unit End Play
470
Manual Linkage
470
Direct Clutch-Forward Clutch
471
Oil Pump (Automatic Transmission)
471
Rear Servo (Automatic Transmission)
472
Control Valve-Governor Screen-Governor Pipes
473
Oil Filter - Oil Pan
473
Modulator - Modulator Valve
473
Extension Housing
474
Transfer Case
474
Automatic Transmission Specifications
474
Clutch Plate Application Table
475
Hydraulic Flow Charts
480
Model 20 Transfer Case
488
Transfer Case Shift Sequence
488
Model 20 Transfer Case In-Vehicle Service
490
Front - Rear Yoke Oil Seal Replacement
491
Rear Bearing Cap - Speedometer Drive Gear Service
491
Model 20 Transfer Case Out-Of-Vehicle Service
493
Transfer Case Removal
493
Transfer Case Installation
493
Transfer Case Disassembly
493
Model 20 Transfer Case View
494
Transfer Case Cleaning and Inspection
495
Transfer Case Assembly
495
Shift Control Case
496
Shift Linkage - CJ Models
498
Model 20 Transfer Case Specifications
498
Quadra-Trac Transfer Case
499
Emergency Drive
500
Reduction Unit
502
Towing - Automatic Transmission with Quadra-Trac Less Reduction Unit
503
Towing - Automatic Transmission with Quadra-Trac and Reduction Unit
503
Transfer Case Service Diagnosis (Quadra-Trac)
504
Emergency Drive System Service Diagnosis
506
Transfer Case Lubrication (Quadra-Trac)
508
Torque Bias Test (Quadra-Trac)
508
Drive Chain Tension Inspection (Quadra-Trac)
508
Reduction Unit Service
509
Transfer Case Service - In-Vehicle
515
Quadra-Trac Transfer Case Components View
516
Transfer Case Service - Out-Of-Vehicle
519
Transfer Case Removal (Quadra-Trac)
519
Transfer Case Installation (Quadra-Trac)
519
Drive Sprocket Oil Seal Replacement
519
Transfer Case Disassembly (Quadra-Trac)
520
Subassembly Overhaul (Quadra-Trac)
520
Bearing Replacement (Quadra-Trac)
522
Control Diaphragm - Shift Fork - Lockup Hub Removal and Installation
524
Transfer Case Assembly (Quadra-Trac)
524
Transfer Case Specifications (Quadra-Trac)
525
Propeller Shaft
528
Universal Joint Application
529
Driveline Vibration
530
Driveline Vibration Diagnosis and Repair (DARS) Charts
531
Universal Joint Angle Measurement and Adjustment
536
Propeller Shaft Lubrication
536
Propeller Shaft Service
537
Universal Joint Service
537
Propeller Shaft Specifications
539
Universal Joint Angle Chart
539
Axles
542
Axle Testing and Diagnosis
542
Front Axle
543
Axle Noisy on Pull and Coast
543
Axle Noisy on Pull
543
Backlash
543
Front Axle Assembly View
544
Axle Identification
545
Axle Housing Service
545
Front Wheel Alignment
545
High Steering Effort
545
Pinion Seal and Yoke Removal and Installation
546
Ball Stud Preload Correction
546
Axle Shaft Removal and Installation
547
Axle Shaft Universal Joint Replacement
548
Steering Knuckle Removal
548
Steering Knuckle Ball Studs
550
Steering Knuckle Installation
551
Axle Shaft Seal Replacement
552
Spindle Bearing Replacement
552
Axle Removal
553
Axle Installation
553
Turning Angle Adjustment
553
Front Axle Specifications
554
Rear Axle
555
Rear Axle Housing
555
Axle Hub - Amc/Jeep Axle
556
Axle Shaft and Bearing
557
Pinion Seal and Yoke
559
Rear Axle Removal
560
Rear Axle Installation
560
Rear Axle Specifications
561
Standard Differential
562
Differential Ovehaul - Amc/Jeep Axle
562
Differential Disassembly
562
Differential Bearing Removal
563
Ring Gear Removal
564
Pinion Mate Shaft Removal
564
Pinion Bear Bearing Removal
564
Pinion Bearing Cup Removal
564
Differential Cleaning and Inspection
565
Differential Assembly
565
Pinion Variance Chart
566
Pinion Gear Installation and Depth Adjustment
566
Pinion Gear Bearing Preload Adjustment
568
Differential Case Assembly
569
Differential Bearing Adjustment
569
Ring Gear Installation
569
Ring and Pinion Gear Backlash Adjustment
569
Differential Bearing Preload Adjustment
570
Differential Overhaul
571
Pinion Depth Measurement and Adjustment
575
Pinion Installation and Depth Adjustment
576
Pinion Bearing Preload Adjustment
577
Differential Side Gear Adjustment
577
Pinion Bearing Preload and Ring Gear Backlash Adjustment
578
Differential Specifications
580
Trac-Lok Differential
581
Trac-Lok Lubricant Change
582
Trac-Lok Differential Diagnosis
582
Trac-Lok Operational Test
582
Trac-Lok Differential Overhaul
583
Trac-Lok Differential Assembly
585
Service Replacement (Trac-Lok)
587
Axles Specifications
587
Brakes
594
Brake Diagnosis
594
Brake Pedal
607
Brake Warning Lamp
607
Parking Brake Adjustment
608
Parking Brake Cables Removal and Installation
609
Brakelamp Switch
610
Service Brake Adjustment
610
Brakelining Inspection
610
Drum Brakes
611
Brake Size and Application Chart
612
Brake Hydraulic System
613
Brake Fluid
613
Brake Fluid Level
614
Hydraulic System Inspection
614
Master Cylinder
614
Wheel Cylinder
616
Combination Valve
617
Brake Bleeding
619
Brake Fluid Specifications
620
Power Brake Units
622
Power Unit Service
624
Power Unit Diagnosis
624
Power Unit Removal
624
Power Unit Installation
624
Drum Brakes Operation
625
Wear Compensation
626
Parking Brake Operation
626
Brake Service - CJ Models
627
Brake Service - Cherokee-Wagoneer-Truck Models
629
Brakes Specifications
631
Disc Brakes
632
Wear Compensation (Disc Brakes)
634
Brakeshoe Replacement - Cherokee-Wagoneer-Truck Models
635
Caliper Overhaul - Cherokee-Wagoneer-Truck Models
636
Brakeshoe Replacement - CJ Models
638
Caliper Overhaul - CJ Models
641
Rotor Service
643
Rotor Measurement
644
Rotor Refinishing
645
Rotor Replacement
645
Wheels and Tires
648
Tire Construction
648
Identifying Tire Types
648
Tire Size and Load Rating
649
Tire Inflation Pressure and Capacity
649
Abnormal Tire Wear
650
Adjusting Inflation Pressures
650
Tire Maintenance and Condition
651
Tire Repair
651
Wide Tread Bias-Belted Tire Wear
651
Tire Rotation
652
Radial, Wide Tread and Snow Tire Applications
652
Wheels Maintenance and Condition
652
Wheel Balancing
653
Wheel Bearing Adjustment
653
Rear Wheel Bearing Adjustment
654
Tire Roughness
655
Radial Tire Performance Characteristics
655
Tire Thump
655
Tire Tramp
655
Wheel and Tire Runout
656
Vibration Types
657
Vibration Diagnosis
657
Wheels and Tires - Vibration Diagnosis Chart
659
Tire Inflation Pressure Chart (PSI)
660
Steering Columns Service Diagnosis
662
Steering Column Alignment
671
Steering Wheel Removal
671
Steering Wheel Installation
671
Sport Steering Wheel Skirt Replacement
672
Steering Column Removal
672
Steering Column View
673
Steering Column Installation
674
Steering Column Overhaul - Manual Transmission
674
Standard Column Ovehaul - Automatic Transmission
681
Tilt Column Overhaul - Cherokee-Wagoneer-Truck Models
685
Tilt Column Overhaul - CJ Models
691
Turn Signal and Cruise Command Switch Removal and Installation
697
Neutral Safety Switch Adjustment, Removal and Installation
698
Ignition Switch Removal and Installation
698
Ignition Lock Cylinder Removal and Installation
699
Lock Cylinder Disassembly
700
Lock Cylinder Assembly
701
Steering Columns Specifications
702
Manual Steering Gear
704
Steering Gear - Left Hand Drive Vehicles
706
Steering Gear Specifications
706
Subassembly Overhaul
709
Wormshaft and Ball Nut
709
Worm Bearing Adjuster
709
Steering Gear Housing and Pitman Shaft
710
Manual Steering Gear Assembly and Adjustment
711
Steering Gear Specifications - Left Hand Drive Vehicles
713
Steering Gear - Right Hand Drive Vehicles
714
Steering Gear Specifications - Right Hand Drive Vehicles
716
Power Steering Gear and Pump
718
Power Steering Pump
719
Hydraulic Assist
719
Fluid Flow - Right Turn Position (Power Steering Gear)
721
Fluid Flow - Left Turn Position (Power Steering Gear)
722
Service Diagnosis - Steering Gear and Pump
723
Variable Ratio Power Steering
723
Leak Diagnosis (Power Steering Gear)
727
Leak Diagnosis and Correction - Pump
728
Power Steering Pump Leak Diagnosis and Corrective Action
731
Hydraulic Pressure Test (Power Steering Gear)
732
Power Steering Gear and Pump Periodic Maintenance
732
Power Steering Gear and Pump Specifications
735
Drive Belt Tension Specifications
735
Power Steering Gear In-Vehicle Service
736
Pitman Shaft Seal Replacement
736
Steering Gear Removal
737
End Plug O-Ring Seal Replacement
737
Power Steering Gear Installation
738
Power Steering Gear Disassembly
739
Steering Gear Subassembly Overhaul
741
Adjuster Plug Disassembly, Cleaning and Inspection
743
Adjuster Plug Assembly
744
Valve Body
745
Pitman Shaft and Side Cover
747
Rack Piston and Wormshaft
747
Steering Gear Assembly and Adjustment
749
Steering Gear Adjustment
750
Wormshaft Bearing Preload
751
Pitman Shaft Overcenter Drag Torque
752
Power Steering Gear Specifications
753
Power Steering Pump In-Vehicle Service
754
Pump Shaft Seal and Pump Pulley Removal and Installation
754
Belt Tension Adjustment (Power Steering Pump)
755
Flow Control Valve Removal and Installation
755
Power Steering Pump Removal
756
Fluid Level and Initial Operation (Power Steering System)
756
Power Steering Pump Installation
757
Power Steering Pump Disassembly
757
Power Steering Pump Cleaning and Inspection
758
Power Steering Pump Assembly
758
Pump Ring Dowel Hole Locations
759
Power Steering Pump Specifications
760
Steering Linkage
762
Tire Rod Removal and Installation
764
Connecting Rod
764
Steering Damper Removal and Installation
764
Camber
765
Steering Wheel Spoke Alignment
766
Front Wheel Shimmy
766
Steering Linkage Specifications
767
Suspension
768
Front Axle Windup Bumper
768
Shock Absorbers
768
Front Spring and Shock Absorber View - CJ Models
769
Stabilizer Bar
770
Front Spring Removal and Installation
770
Shock Absorber Replacement
770
Front Spring and Shock Absorber View - Cherokee-Wagoneer-Truck Models
770
Rear Spring and Shock Absorber View - CJ Models
771
Rear Spring and Shock Absorber View - Cherokee-Wagoneer-Truck Models
772
Rear Spring Removal and Installation
773
Spring Bushing Replacement
774
Suspension Specifications
775
Large Bushing
775
Body
776
Water Leak/Wind Noise Diagnosis and Repair
778
Spray Test
778
Ultrasonic Test
778
Light Test
778
Water/Rust Streaks
779
Water in Front Passenger Compartment
779
Front Floorpan, Side Sills, Cowl Side Panels or Front Hinge Pillars
780
Water on Front or Rear Seats
781
Water off Headliner
782
Water in Rear Passenger Compartment
783
Water in Cargo Area
784
Interior Wind Noises
786
Static Test (Wind Noises)
786
Road Test (Wind Noises)
786
Exterior Wind Whistles
787
Road Test (Wind Whistles)
787
Grille Area (Wind Whistles)
787
Fender Mouldings
788
Body Mouldings
788
Luggage Racks and Wind Whistles
788
Metal Repair and Painting
790
Paint Repair with Acrylic Enamel
790
Finishing Metal Replacement Parts
791
Painting Tips
791
Metallic Color Guide
791
Finishing Plastic Trim Parts
792
Test for Polypropylene and ABS Plastic
792
Test for Vinyl Plastic
792
Procedure for Painting Flexible Vinyl Plastic Parts
792
Instrument Panels and Components
794
CJ Instrument Panel Removal and Installation
794
Instrument Cluster (CJ)
794
Crash Pad Removal and Installation
795
Instrument Illumination
796
Glove Box Assembly Removal and Installation
796
Glove Box Door and Hinge Removal and Installation
796
Speedometer Removal and Installation
796
Cherokee - Wagoneer - Truck Instrument Panel
797
CJ Heater
802
Heater and Defroster Operation
803
Fresh Air Ventilation
803
Fresh Air Intake View
804
CJ Service Diagnosis
804
Fan Control Switch Removal and Installation
805
Control Cables Adjustment and Replacement (CJ Heater)
805
Heater Core Removal and Installation
805
Blower Motor
805
Defroster Duct Removal and Installation
806
Fresh Air Intake Duct Removal and Installation
806
Cherokee - Wagoneer - Truck Heater
807
Air Conditioning
812
Air Conditioning General Service Procedures
813
Refrigerant Safety Precautions
813
Service Valves (Air Conditioning)
814
Pressure Gauge and Manifold Assembly
815
Checking System Pressures (Air Conditioning)
815
Sight Glass
817
Discharging System
817
Evacuating System
817
Checking for Leaks (Air Conditioning)
819
Halide Torch Leak Detection
819
Charging the Air Conditioning System
820
Electronic Leak Detection (Air Conditioning)
820
Filling Charging Cylinder
820
Charge Capacity
821
Compressor Overview
822
Compressor Valve Leak Diagnosis
822
Compressor Belt Tension
822
Isolating the Compressor
823
Compressor Removal and Installation
823
Back Plate O-Ring Seal Replacement
824
Compressor Seal Components and Gaskets View
824
Head, Valve Plate and Gasket Replacement
825
Bottom Plate Gasket Replacement
825
Checking Compressor Oil Level
826
Purging Compressor of Air
826
Flushing System
827
Magnetic Clutch Removal and Installation
827
Diagnosis for Noisy Clutch (Air Conditioning)
827
Magnetic Clutch Troubleshooting
829
Air Conditioning Performance Diagnosis
830
Air Conditioning - Pressure Diagnosis
831
CJ Air Conditioning
833
Cherokee - Wagoneer - Truck Air Conditioning
836
Body and Frame Components
840
Body Construction
840
Trim Mouldings/Rocker Panel Mouldings
840
Frame Construction
840
Panels
846
Rear Quarter Panels
847
Radiator Grilles
847
Fenders
848
Bumpers
850
Swingout Spare Tire Carriers
852
Roll Bars
853
Brush Guards
854
Hoods
856
Hood Lock
858
Hood Bumper
858
Liftgates - Tailgates
860
Sealing System
860
Window System
860
Lock System
861
Outside Handle Replacement
861
Support System Replacement
862
Hinge System Replacement
862
Liftgate Removal and Installation
862
Liftgate Alignment
862
CJ-5 Tailgate
863
CJ-7 Tailgate
863
Cherokee - Wagoneer Tailgates
864
Power Tailgate Window System
867
Power Tailgate Window Circuitry - Cherokee, Wagoneer Models
868
Truck Tailgate
870
Doors
872
Door Trim
872
Door Assist Handle Removal and Installation
872
Water Shield
872
Door Glass
873
Stationary Vent Window
874
Window Regulator
874
Latch Replacement
874
Cherokee - Wagoneer - Truck Front Doors
875
Cherokee - Wagoneer - Rear Doors
880
Vent Window Removal and Installation
882
Wingow Regulator Removal and Installation
882
Locking Rod Removal and Installation
882
Remote Control and Lock Lever Rod Removal and Installation
882
Rear Quarter
884
Trim Panel Removal and Installation
884
Pivot Vent Window (Cherokee) Removal and Installation
884
Stationary Window - 2-Door Cherokee
885
Stationery Window 4-Door Cherokee - Wagoneer
885
Luggage Racks
888
Seat Assemblies
892
Front Seats
892
CJ Bucket Seats
892
CJ 2/3-1/3 Style Seats
892
Cherokee - Wagoneer - Truck Bucket Seats
895
Cherokee-Wagoneer-Truck Bench Seats
895
Forward Tilting Seat Back Replacement - Cherokee and Truck Models
895
Tilt Lock Pawl Assembly
895
CJ Floor Console
896
Console Cover Lock
896
Rear Seats
897
Seat Belts Removal and Installation
897
Windshield
900
CJ Folding Windshield Removal and Installation
900
Cherokee-Wagoneer-Truck Windshield Glass
901
Rear View Mirror Bracket Installation
904
Rear Window Specifications
905
Headlining - Hardtop - Exterior Decals and Overlays
908
Hardtop Enclosure
909
Hardtop Enclosure Dent Repair
910
Hardtop Enclosure Broken Section Repair
911
Hardtop Enclosure Fracture Repair
911
Hardtop Enclosure Paint Repair
912
Sun Roof
913
Glass/Frame Assembly Removal and Installation
913
Glass Frame Weatherseal
913
Metal Frame/Clamp Ring
913
Exterior Decals
914
Installation of Intricate Decals
917
Exterior Woodgrain Overlays
918
Vinyl Moulding Replacement
918
Exterior Lighting Systems
922
Headlamps Replacement
922
Headlamp Aiming Procedure
923
Headlamp Switch Replacement
923
Dimmer Switch Replacement
924
Parking, Side Marker and Directional Lamps
925
Rear Directional, Side Marker, Stop and Taillamps
926
Backup Lamps and Switches
927
Cargo Lamp
928
Directional Signal Switch Removal and Installation
928
4-Way Emergency Flasher (Hazard Warning)
930
Stoplamp Switch
930
Off-Road Driving Lamps Aiming
931
Off-Road Driving Lamps - Lamp Element Replacement
931
Engine Compartment Lamp
932
Interior Lighting System
933
Courtesy Lamps/Dome Lamps
933
Dome/Reading Lamp
933
Lighted Vanity Mirror
934
Glove Box Lamp
934
Chassis Wiring Harness
935
Main Harness Connector
935
Fusible Link Replacement (Chassis Wiring Harness)
935
Ignition Switch Testing
936
Ignition Switch Installation
937
Fuse Panel
937
Circuit Breakers
937
Horn System Diagnosis and Repair
940
Horn Adjustment
941
Windshield Wipers
942
Wiper Blade Replacement
942
Wiper Arm Replacement
943
Pivot Shaft Body and Linkage
943
Wiper and Washer Control
943
Washer Pump
944
Cherokee - Wagoneer - Truck Windshield Wiper
945
Windshield Wiper Circuitry
953
Windshield Wiper with Intermittent Governor Circuitry
954
Control Switch Removal and Installation
955
Control Switch Test
955
Circuit Breaker Test
955
Intermittent Governor
956
Wiper Motor Removal and Installation
956
Current Draw Test - on Vehicle
956
Park Test
957
Wiper Motor and Transmission Components View
958
Windshield Wiper Specifications
959
Tailgate Window Defogger
960
Heated Rear Window Wiring Diagram
960
Tailgate Window Defogger Testing
961
Radio Sound Systems
964
Setting the Pushbuttons
964
Radio Polarity
964
Antenna Trimmer
965
Radio Sound System Controls
965
CB Radio Controls
966
CB Operation
966
Tape Player Operation
966
Tape Head and Capstan Cleaning
966
Radio Reception Characteristics
967
Radio Interference Diagnosis
969
Noise Radiated from the Engine Compartment
970
Primary Ignition Noise
970
Secondary Ignition Noise
970
A-Line (Power Feed Wire to Radio)
970
Alternator Wine (A-Line)
971
Wiring Harness Close to Ignition Wiring
971
Instrument Cluster Radle Noise Suppressor
971
Speaker Leads
971
Radio Replacement
972
Wheel and Tire Static
972
Turn and Stop Signals
972
Horn Noise
972
Bulb Replacement (Radio)
973
Operating Instructions for Tester
973
CB Radio Frequency Chart
973
Antenna Tests
974
AM/FM/CB Radio
974
Tuning the CB Antenna/Splitterbox
974
VSWR Reading by CB Channels
974
Speaker Repairs
975
Radio Bulb Chart
976
Speaker Harness Test
976
Speaker Test
976
Radio Speaker Replacement
976
Alphabetical Index
980
Vacuum Line Routing Diagrams
1005
Wiring Diagrams
1028
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