Rear (Trac-Lok) (4) .......................... 2.5 Pts. (1.2L)
(
1) - Capacities are recommended or calculated levels. Always use
dipstick (if available) to measure level.
(
2) - Includes 2.3 qts. for coolant recovery bottle.
(
3) - Fill to bottom of filler plug hole.
(
4) - Add 4 ozs. (118 ml) of Limited-Slip differential lubricant
additive first, then add new fluid.
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90,000 MILE (144,000 KM) SERVICE
90,000 MILE (144,000 KM) SERVICE \
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Service Or Inspect
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Verify Last Major Service Was Performed
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Check Fluid Levels
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Check Fuel Lines, Connections
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Check Cooling System Hoses and Clamps
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Check Coolant Strength
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Clean Battery and Battery Terminals
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Accessory Drive Belts
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Clean Choke Linkage
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Check Exhaust System & Heat Shielding
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Check Operation of Horn, Wipers/Washers & All Exterior Lights
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Inspect Condition of Wiper Blades
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Check Headlight Alignment
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Check Seat Belt Webbing and Release Mechanisms
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Check Parking Brake Operation
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Check Shift/Clutch Interlock Operation
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Adjust Drive Belt Tension
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Inspect C/V Joint boots (4WD)
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Inspect Underside of Vehicle (Bolts & Threaded Fasteners)
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Check/Lube Manual Steering Gear
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Check Drive Shaft Seals
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Lubricate Ball Joints, Steering Linkage & Suspension
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Lube Drive Shaft U-Joints and Slip Splines
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Lube Front Axle Drive Joint and Pivot Bearings (4WD)
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Clean Battery and Battery Terminals
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Inspect Brake System
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Check Operation of Horn, Wipers/Washers & All Exterior Lights
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Inspect Condition of Wiper Blades
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Check Headlight Alignment
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Check Seat Belt Webbing and Release Mechanisms
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Check Parking Brake Operation
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Check Shift/Clutch Interlock Operation
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Inspect C/V Joint boots (4WD)
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Inspect Underside of Vehicle (Bolts & Threaded Fasteners)
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Check/Lube Manual Steering Gear
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Check Drive Shaft Seals
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Lubricate Ball Joints, Steering Linkage & Suspension
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Lube Drive Shaft U-Joints and Slip Splines
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Lube Front Axle Drive Joint and Pivot Bearings (4WD)
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Inspect Front Wheel Bearings (4WD)
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Lubricate Weatherstripping with Silicone
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Lubricate Door Hinges
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Lubricate Door Locks
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Check Body Drain Holes
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Rotate Tires and Adjust Air Pressure
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Replace
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Engine Oil
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Oil Filter
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Flush and Fill Engine Coolant, if not done in last 24 months
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Lubrication Specifications
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Application Specification
Automatic Transmission .......................... Dexron-IIE ATF
Brake Master Cylinder .......... DOT 3 (SAE J-1703F) Brake Fluid
Engine Coolant ........... Alugard 340-2 & Water (50/50 Mixture)
Engine Oil (
1)
Gasoline Engine
Temperature Range
Above 30
F (-1
C) ........ SAE 20W-40 Or 20W-50 API SH/CD
Above 0
F (-18
C) ......... SAE 10W-30 Or 10W-40 API SH/CD
Less Than 60
F (16
C) ............... SAE 5W-30 API SH/CD
1988
Selec-Trac ................................. 3.0 Pts. (1.4L)
Command-Trac ............................... 2.2 Pts. (1.0L)
Drive Axles (
3)
Front ........................................ 2.5 Pts. (1.2L)
Front (Disconnect Housing) .................. 5.0 Ozs. (0.15L) \
Rear ......................................... 2.5 Pts. (1.2L)
Rear (Trac-Lok) (
4) .......................... 2.5 Pts. (1.2L)
(
1) - Capacities are recommended or calculated levels. Always use
dipstick (if available) to measure level.
(
2) - Includes 2.3 qts. for coolant recovery bottle.
(
3) - Fill to bottom of filler plug hole.
(
4) - Add 4 ozs. (118 ml) of Limited-Slip differential lubricant
additive first, then add new fluid.
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112,500 MILE (180,000 KM) SERVICE
112,500 MILE (180,000 KM) SERVICE \
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Service Or Inspect
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Verify Last Major Service Was Performed
\b\
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Check Fluid Levels
\b\
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Check Cooling System Hoses and Clamps
\b\
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Check Coolant Strength
\b\
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Clean Battery and Battery Terminals
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Check Exhaust System & Heat Shielding
\b\
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Check Operation of Horn, Wipers/Washers & All Exterior Lights
\b\
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Inspect Condition of Wiper Blades
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Check Headlight Alignment
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Check Seat Belt Webbing and Release Mechanisms
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Check Parking Brake Operation
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Check Shift/Clutch Interlock Operation
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Inspect C/V Joint boots (4WD)
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Inspect Underside of Vehicle (Bolts & Threaded Fasteners)
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Check/Lube Manual Steering Gear
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Check Drive Shaft Seals
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Lubricate Ball Joints, Steering Linkage & Suspension
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Lube Drive Shaft U-Joints and Slip Splines
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Lube Front Axle Drive Joint and Pivot Bearings (4WD)
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Lube Parking Brake Ratio Lever Pivot
4) Tap end of sector shaft with a soft-faced hammer to free
shaft from housing, then remove sector shaft. Remove adjuster plug
lock nut. Remove adjuster plug with a spanner wrench.
5) Insert a rack/piston arbor into end of rack/piston until
arbor just contacts worm shaft. Turn stub shaft counterclockwise to
force rack/piston onto arbor. Remove rack/piston and arbor as an
assembly.
6) Take care to keep arbor fully inserted so ball bearings
will not fall out. Remove input shaft and control valve assembly from
housing. Remove worm, wormshaft lower thrust bearing, and races from
housing.
Reassembly
1) Lubricate all parts with clean power steering fluid before
reassembly. Install the lower thrust bearing and races onto the worm.
Cupped side of thrust washers must face toward stub shaft. See Fig. 8.
Fig. 8: Reassembly of Valve Body & Worm Shaft Assembly
NOTE: If conical thrust races are used, ensure tapered surfaces
are parallel to each other and that cupped sides face toward
stub shaft.
housing ball plug for fluid leakage. Seat ball plug with blunt punch.
2) Spray ball area with Loctite Solvent 7559 and dry with
compressed air. Cover ball area with Loctite Sealant 290. Allow
sealant to cure for 2 hours before assembling gear.
3) Inspect all retaining ring, bearing and seal surfaces in
housing. Replace housing if any surface is worn or damaged.
Reassembly
1) Working from upper end, press a new bearing into housing
until it is seated .030" (.76 mm) below shoulder in housing bore.
Lubricate new seal with power steering fluid.
2) Install single lipped seal and spacer washer only far
enough to provide clearance for next seal, washer and retaining ring.
DO NOT bottom seal against housing counterbore.
3) Install double lipped seal and steel washer. Install
retaining ring. DO NOT allow seals to contact one another. To ensure
proper seal action, be sure there is clearance between them.
4) If port seat was removed, position new spring, check
valve, and a new seat over opening in housing. Drive into place using
a brass drift.
TORQUE SPECIFICATIONS
CHEROKEE, COMANCHE, WAGONEER & WRANGLER
TORQUE SPECIFICATIONS (CHEROKEE, COMANCHE, WAGONEER & WRANGLER) \
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Application Ft. Lbs. (N.m)
Adjuster Plug Lock Nut .......................... 80 (108)
Gear Housing-to-Frame Attaching Bolts ........... 75 (102)
Pitman Arm Attaching Nut ....................... 185 (250)
Rack Piston End Plug ............................. 50 (68)
Sector Shaft Adjuster Lock Nut ................... 33 (45)
Side Cover Bolts ................................. 45 (60)
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GRAND WAGONEER & "J" TRUCK)
TORQUE SPECIFICATIONS (GRAND WAGONEER & "J" TRUCK) \
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Application Ft. Lbs. (N.m)
Adjuster Plug Lock Nut .......................... 85 (116)
Gear Housing-to-Frame Attaching Bolts ............... (95)
Pitman Arm Attaching Nut ....................... 185 (250)
Rack Piston End Plug ............................ 75 (102)
Sector Shaft Adjuster Lock Nut ................... 33 (45)
Side Cover Bolts ................................. 40 (54)
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Will Not Shift Or Difficult To Shift Into Gear
Vehicle speed too high; slow vehicle to 2-3 MPH to shift.
Vehicle operated too long on dry paved surface; stop vehicle and place
in Reverse or Neutral to relieve driveline torque. Ensure transfer
case external linkage is not binding. Ensure correct fluid is used.
Internal parts may be worn or damaged.
Noisy In All Gears
Check fluid level. Ensure correct fluid is used. If fluid is
okay, locate possible internal mechanical problem.
Jumps Out Of Gear Or Noisy In 4WD
Transfer case not completely in gear; check shift linkage.
Range fork damaged. Shift fork pads are worn or shift fork binding.
Low range gear worn.
Fluid Leaking From Vent Or Seals
Transfer case overfilled. Vent plugged. Output shaft seals
are damaged or not installed properly.
ON-VEHICLE SERVICE
FRONT OIL SEAL
Removal & Installation
1) Mark front drive shaft and flange for installation
alignment reference. Remove front drive shaft. Remove flange. Discard
washer and nut. Using a screwdriver, carefully remove oil seal. Ensure
seal contact surface is clean.
2) Apply ATF to seal lip and flange seal surface. Install NEW
oil seal. Install flange and NEW washer and nut. Tighten nut to
specifications. See TORQUE SPECIFICATIONS . Install front drive shaft
using alignment marks. Check transfer case fluid.
EXTENSION HOUSING OIL SEAL & BUSHING
Removal & Installation
1) Mark rear drive shaft and flange for installation
alignment reference. Remove rear drive shaft. Tap extension housing in
a clockwise direction and remove extension housing. DO NOT pry on
extension housing. Using a screwdriver, remove oil seal from extension
housing.
2) Using bushing driver, replace bushing in extension
housing. Install NEW extension housing oil seal. Apply silicone
sealant to extension housing mating surface. Install extension
housing. To complete installation, reverse removal procedure.
REMOVAL & INSTALLATION
TRANSFER CASE
Removal
1) Shift transfer case into 4H and disconnect battery
negative cable. Raise vehicle, remove skid plate and drain fluid.
2) Mark front and rear output shaft yokes to drive shafts for
reassembly reference. Support transfer case and remove rear
crossmember. Remove drive shafts.
3) Disconnect vehicle speed sensor electrical connector and
vacuum (hoses) harness at transfer case. Remove shift lever or linkage\
rod from case. Remove transfer case attaching bolts. Remove transfer
case from vehicle.
Removal & Installation
1) Mark front propeller shaft and flange for alignment
purposes. Remove front propeller shaft. Remove flange. Discard washer
and nut. Using a screwdriver, carefully remove oil seal. Ensure seal
contact surface is clean.
2) Apply ATF to seal lip and yoke seal surface. Install oil
seal and flange with new washer and nut. Install front propeller shaft
using alignment marks. Check transfer case fluid.
EXTENSION HOUSING OIL SEAL & BUSHING
NOTE: When replacing oil seal, DO NOT remove extension housing.
Removal & Installation
1) Mark rear propeller shaft and flange for installation
purposes. Remove rear propeller shaft. Remove bolts and tap extension
housing in a clockwise direction and remove extension housing. DO NOT
pry on extension housing. Using a screwdriver, remove oil seal from
extension housing.
2) Using bushing driver, replace bushing in extension
housing. Install new extension housing oil seal. Apply silicone
sealant to extension housing mating surface. Install extension
housing. Reverse removal procedure to complete installation.
REMOVAL & INSTALLATION
TRANSFER CASE
Removal & Installation
1) Shift transfer case into Neutral position and drain fluid.
Mark front and rear drive shaft for installation purposes. Remove
front and rear drive shafts. Disconnect vacuum lines and speedometer
cable. Remove rear crossmember.
2) Disconnect shift linkage. Support transfer case with a
jack. Separate transfer case from transmission. Remove transfer case.
To install, reverse removal procedure. Tighten bolts to specification.
See TORQUE SPECIFICATIONS . Adjust shift linkage, if necessary.
TRANSFER CASE DISASSEMBLY
1) Remove drain and fill plugs. See Fig. 1. Remove front
companion flange, washer and seal. Place transfer case in 4L position.
Remove extension housing. See EXTENSION HOUSING OIL SEAL & BUSHING
under ON-VEHICLE SERVICE. Remove rear bearing snap ring. Remove rear
bearing retainer. Separate rear case from front case using prybars or
screwdriver. DO NOT damage mating surfaces.
NOTE: DO NOT disassemble oil pump, replace as unit only.
2) Remove oil pump, pick-up tube and screen from rear case.
Remove pick-up tube "O" ring from oil pump. Remove magnet from front
case. Remove drive sprocket snap ring. Remove drive sprocket and drive
chain.
3) Remove front output shaft. Remove shift lever from sector
shaft. Remove shift detent plug, spring and plunger. Remove plug from
low range fork lock pin access hole. Move shift sector until lock pin
is aligned with hole. Remove lock pin with No. 1 screw extractor.
4) Remove shift rail from fork assembly. Remove mode fork and
mainshaft as an assembly. Record mode sleeve position. Remove mode
shift sleeve and mode fork assembly. Remove sleeve from fork. Remove