1994 JEEP CHEROKEE automatic transmission

SHIFT LINKAGE ADJUSTMENT
(1) Remove shift lever bezel.
(2) Move shift lever into 4L position.
(3) Insert 3 mm (1/8 in.) spacer between shift lever
and forward edge of shift lever gate (Fig. 4). Secure
lever and spacer in place with tape or wire.
(4) Raise vehicle.
(5) Loosen trunnion lock bolt (Fig. 5). Linkage rod
should now slide freely in trunnion.
(6) Verify that transfer case range lever is in 4L posi-
tion.
(7) Position linkage rod so it is free fit in range le-
ver (Fig. 5). Then tighten trunnion lock bolt.
(8) Lower vehicle.
(9) Remove shift lever spacer and install bezel.
SPEEDOMETER SERVICE
Speedometer service is covered in the automatic
transmission sections within this group.
TRANSFER CASE REMOVAL
(1) Shift transfer case into Neutral.
(2) Raise vehicle.
(3) Drain transfer case lubricant.
(4) Mark front and rear propeller shaft yokes for
alignment reference.
(5) Place support stand under transmission.
(6) Remove rear crossmember.
(7) Disconnect front/rear propeller shafts at trans-
fer case.
(8) Disconnect vehicle speed sensor wires and re-
move sensor and adapter assembly if necessary.
(9) Disconnect transfer case shift rod from range lever.
(10) Disconnect transfer case vent hoses and elec-
trical switch connector.
(11) Support transfer case with transmission jack.
(12) Remove bolts attaching the transfer case to
transmission.
(13) Secure transfer case to jack with chains.(14) Pull transfer case and jack rearward to disen-
gage transfer case.
(15) Remove transfer case from under vehicle.
TRANSFER CASE INSTALLATION
(1) Mount transfer case on transmission jack. Se-
cure transfer case to jack with safety chains.
(2) Position transfer case under vehicle.
(3) Align transfer case and transmission shafts and
install transfer case on transmission.
(4) Install and tighten transfer case attaching nuts
to 35 Nzm (26 ft. lbs.) torque.
(5) Install vehicle speed sensor and adapter, if re-
moved. Then connect vehicle speed sensor wires, vent
hoses and electrical switch connector.
(6) Align and connect propeller shafts. Tighten shaft
U-joint clamp bolts to 19 Nzm (14 ft. lbs.) torque.
(7) Fill transfer case with recommended automatic
transmission fluid.
(8) Install rear crossmember. Tighten crossmember
bolts to 41 Nzm (30 ft. lbs.) torque.
(9) Remove transmission jack and transmission
support stand.
(10) Connect transfer case range lever to shift rod.
(11) Check and adjust transfer case shift linkage if
necessary.
(12) Lower vehicle.
Fig. 4 Installing Shift Lever Spacer
Fig. 5 Transfer Case Shift Linkage
21 - 296 NP242 TRANSFER CASEJ

Inspect the differential gears, thrust washers and
case halves. Replace the mainshaft gear if the gear
teeth or the brass ring on the underside of the gear
are damaged. Replace the differential as an assembly
if the gears, case halves, or the pins in the lower case
half are damaged.
Inspect the case halves, extension housing and re-
tainers for cracks, porosity, or damaged sealing sur-
faces. Inspect the shafts, gears, chain and shift
components for wear or damage.
Inspect all of the transfer case bearings for wear,
roughness, pitting, or galling. Replace worn or dam-
aged bearings as outlined in the assembly section.
TRANSFER CASE ASSEMBLY
(1) Lubricate the transfer case components with
automatic transmission fluid or petroleum jelly
(where indicated) during assembly.
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Be sure re-
placement bearings do not block these feed holes.
(2) Remove the front output shaft, front bearing
snap ring (Fig. 42).(3) Remove the old bearing and install the new
bearing with a driver handle and installer tool (Fig.
43).
(4) Install the front bearing snap ring (Fig. 42).
(5) Install new front output shaft oil seal (Fig. 44).
Fig. 42 Removing/Installing Front Output Shaft
Front Bearing Snap Ring
Fig. 43 Replacing Output Shaft Front Bearing
Fig. 44 Installing Front Output Shaft Seal
21 - 306 NP242 TRANSFER CASEJ

(11) Assemble low range gear, input gear thrust
washers, input gear and input gear retainer (Fig. 49).
(12) Install low range gear snap ring (Fig. 50).
(13) Lubricate input gear and low range gears with
automatic transmission fluid.
(14) Start the input gear shaft into the front case
bearing.
(15) Press the input gear shaft into the front bear-
ing.CAUTION: Be sure the input gear installer tool is
the proper size. The wrong size tool could push the
input gear pilot bearing too far into the gear bore
(Fig. 51). Also, do not press against the end sur-
faces of the low range gear. The gear case and
thrust washers could be damaged.
(16) Install new input gear snap ring (Fig. 52).
Fig. 49 Low Range And Input Gear Assembly
Fig. 50 Install Low Range Gear Snap Ring
Fig. 51 Input Gear Installation
Fig. 52 Install Input Gear Snap Ring
21 - 308 NP242 TRANSFER CASEJ

The reinforcement bracket is held on the
frame rail with two blind rivets.
(2) Remove the bracket and tow hook from frame
rail.
INSTALLATION
(1) Position bracket and tow hook on the frame
rail.
(2) Install bolts that attach tow hook bracket to
frame rail and reinforcement bracket. Tighten bolts
to 75 Nzm (55 ft-lbs) torque.
TRAILER HITCHES
CLASS III HITCHÐXJ VEHICLES
A class III weight-distributing/equalizer type hitch
can be used to tow a trailer:
²having a maximum gross weight of 5,000 lbs/2250
kg, and
²having a maximum tongue weight of 750 lbs/332
kg).
The following vehicle basic equipment is required
for class III trailer towing:
²P205/75R15 or larger tires;
²full size spare tire;
²trailer sway control;
²trailer tow wire harness and connector;
²heavy duty turn signal flasher element;
²heavy duty axle (with synthetic lubricant);²heavy duty cooling system;
²heavy duty generator/battery;
²auxiliary automatic transmission fluid cooler; and
²I-6, 4.0L engine.
Wide-angle type door mirrors are recommended but
not required.
WIRE HARNESS CONNECTORS
CLASS I HITCH CONNECTOR
The trailer tow wire harness connector for class I
trailer hitches is a 5-terminal, in-line type connector.
Terminal 5 is the source for vehicle ground.
CLASS III HITCH CONNECTOR
The trailer tow wire harness connector for class III
trailer-tow hitches is a 7-terminal, circular type con-
nector.
The 12-volt circuit for the trailer is protected
from overloads. A auto-reset type circuit
breaker is located in the trailer tow wire har-
ness near the plug-in relays.
CAUTION: The trailer tow wire harness package
does not include a vehicle battery isolator unit. Be-
cause of this, the trailer battery can totally dis-
charge the vehicle battery if the engine is not
operated for an extended period of time.
Fig. 11 Trailer Tow Wire Harness Connectors
23 - 88 BODY COMPONENTSÐXJ VEHICLESJ

PARKING BRAKE HANDLE COVERÐXJ
VEHICLES
REMOVAL
(1) Detach the rear of the cover from the base and
pivot it upward.
(2) Remove the retaining screws from the cover
base.
(3) Remove the trim cover from the from the floor.
INSTALLATION
(1) Position the cover on the floor and install the
retaining screws.
(2) Pivot the cover to the closed position and en-
gage the locking tab.
MINI-CONSOLE WITH FLOOR SHIFT
REMOVAL
(1) Remove the transmission shift lever handle/
knob. For vehicles with an automatic transmission,
pull the handle straight up. For vehicles with a man-
ual transmission, loosen the locknut and un-thread
the shift knob from the shaft.
(2) Remove the automatic transmission and trans-
fer case shift indicator bezel by prying upward to re-
lease them.
(4) Disconnect the lamp socket from the bezel.
(5) Remove the console retaining screws.
(6) Disconnect the wire harness connector.
(7) Remove the mini-console from the transmission
tunnel.
INSTALLATION
(1) Position the mini-console on the transmission
tunnel, connect the wire harness connector and in-
stall the retaining screws. Tighten the screws to 1
Nzm (13 in-lbs) torque.(2) Position the shift indicator bezel at the console
and connect the lamp socket to the bezel. Install the
bezel in the console.
(3) Install the shift lever handle/knob. For auto-
matic transmissions, push the handle downward un-
til it is engaged. For manual transmissions, thread
the knob onto the shaft and tighten the locknut.
FULL FLOOR CONSOLEÐXJ VEHICLES
REMOVAL
(1) Remove the transmission shift lever handle/
knob. For automatic transmissions, pull the handle
straight upward to remove it. For manual transmis-
sions, loosen the locknut and un-thread the shift
knob from the shaft.
(2) Remove the automatic transmission shift indi-
cator bezel. Remove the transfer case shift indicator
bezel (if equipped) or cover plate from the console.
(3) If equipped, insert a thin-blade tool under the
edge of the outside mirror remote control switch and
pry outward to detach it from the console. Disconnect
the wire harness connector from the switch (Fig.
195).
(4) Remove the cover retaining screws and remove
the cover from the console.
(5) Remove the remainder of the console attaching
screws from the brackets and disconnect the wire
harness connector.
(6) Separate the console floor air duct from the air
outlet duct.
(7) Remove the console and air duct from the floor.
(8) Separate the floor air duct from the console.
(9) Remove the retaining screws and detach the
floor duct from the heater housing, if necessary.
(10) Remove the console support brackets.
The brackets are attached directly to the
floor panel below the carpet.
Fig. 142 Park Brake Cover With Mini-ConsoleÐXJ
Vehicles
Fig. 143 Mini-Console With Floor Shift
JBODY COMPONENTSÐXJ VEHICLES 23 - 125

(4) Connect the heater hoses to the heater core.
(5) Fill the cooling system.
HEATER CORE HOUSING REPLACEMENT
(1) Remove the evaporator/blower housing.
(2) Remove the heater core.
(3) Remove the defroster duct.
(4) Disconnect the vacuum hoses from the heater
core housing vacuum motors.
(5) Remove the heater housing retaining nuts in
the engine compartment. Remove the heater core
housing.
(6) Transfer the vacuum motors, etc. to the re-
placement housing.
To install the heater core housing, reverse the re-
moval procedure.
DEFROSTER DUCT REPLACEMENT
REMOVAL
(1) Disconnect negative cable from battery.
(2) If equipped with center console remove the con-
sole as follows:
(a) MANUAL TRANSMISSIONÐRemove shift
knob, boot and bezel.
(b) AUTOMATIC TRANSMISSIONÐRemove
shift handle by pulling up. Remove the shift bezel.
(c) POWER MIRRORSÐPry mirror switch out of
console cover (Fig. 13). Disconnect switch connector
(Fig. 14).
(d) Remove console cover screws (Fig. 14).
(e) Remove console cover from base (Fig. 15).
(f) Remove console base (Fig. 15).
(3) Remove the lower instrument panel.
(4) Remove the left kick panel.
(5) Remove the instrument panel retaining bolt.
(6) Remove the instrument panel retaining bolts
located at the steering column.
(7) Remove the right and left A-pillar trim.(8) Remove the defroster bezel attaching screws
and bezel (Fig. 16).
Fig. 13 Power Mirror Switch
Fig. 14 Console Cover Screws and Power Mirror
Switch Connector
Fig. 15 Console Cover and Base
JHEATING AND AIR CONDITIONING 24 - 29

(9) Remove the instrument panel retaining screws.
(10) Lower the steering column.
(11) Pull the instrument panel, approximately 3
inches, away from the dash panel.
(12) Remove the defroster duct retaining screws.
Remove the defroster duct.
(13) Disconnect the hoses.
INSTALLATION
(1) Connect the hoses.
(2) Install the defroster duct. Install the defroster
duct retaining screws.
(3) Position the instrument panel into the dash
panel.
(4) Position the steering column.
(5) Install the instrument panel retaining screws.
(6) Install the defroster bezel attaching screws and
bezel.
(7) Install the right and left A-pillar trim.
(8) Install the instrument panel retaining bolts lo-
cated at the steering column. Tighten the steering
column retaining nuts to 27 NIm (20 ft. lbs.) torque.
(9) Install and tighten the instrument panel re-
taining bolt.
(10) Install the left kick panel.
(11) Install the lower instrument panel.
(12) If equipped with center console, install the
console as follows:
(a) Install console base.
(b) Install console cover to base.
(c) Install and tighten console cover screws.
(d) POWER MIRRORSÐSnap mirror switch into
the console cover. Connect switch connector.
(e) MANUAL TRANSMISSIONÐInstall shift
knob, boot and bezel.(f) AUTOMATIC TRANSMISSIONÐInstall the
shift bezel. Install shift handle by pushing down.
(13) Connect negative cable to battery.
HEATER CONTROL CABLE REPLACEMENT
(1) Remove the heater control panel.
(2) Remove the clip and the cable self-adjusting
clip from the blend air door lever at the bottom of
the evaporator/blower housing (Fig. 17). Then re-
move the cable by squeezing the tabs with needle
nose pliers being careful not to break the housing.
To install the heater control cable, reverse the re-
moval procedure.
HEATER/DEFROSTER/INSTRUMENT PANEL OUTLET
DOOR VACUUM MOTOR REPLACEMENT
(1) If equipped with center console remove the con-
sole as follows:
(a) MANUAL TRANSMISSIONÐRemove shift
knob, boot and bezel.
(b) AUTOMATIC TRANSMISSIONÐRemove
shift handle by pulling up. Remove the shift bezel.
(c) POWER MIRRORSÐPry mirror switch out of
console cover (Fig. 13). Disconnect switch connector
(Fig. 14).
(d) Remove console cover screws (Fig. 14).
(e) Remove console cover from base (Fig. 15).
(f) Remove console base.
(2) Remove the lower instrument panel.
(3) Disconnect the vacuum hose(s) from the vac-
uum motor.
(4) Remove the vacuum motor attaching nuts and
remove the vacuum motor from the bracket.
Fig. 16 Defroster Bezel
Fig. 17 Heater Control
24 - 30 HEATING AND AIR CONDITIONINGJ

(5) Remove the vacuum motor linkage retaining
clip and remove the rod from the door actuating le-
ver (Fig. 18).
To install a vacuum motor, reverse the removal
procedure.
A/C RECIRCULATING AIR DOOR VACUUM MOTOR
REPLACEMENT
(1) Remove the vacuum motor cover (Fig. 19).
(2) Disconnect the vacuum hose (Fig. 20).(3) Remove the actuating rod clip and disengage
the rod from the door lever.
(4) Remove the vacuum motor retaining nuts and
then remove the vacuum motor.
To install the motor, reverse the removal proce-
dures.
CONDENSER/RECEIVER DRIERÐ2.5L ENGINES
REMOVAL
(1) Drain the radiator.
(2) Disconnect the fan shroud and the radiator
hoses.
(3) Disconnect the transmission cooler lines (if
equipped with automatic transmission).
(4) Evacuate the A/C system. Disconnect the A/C
hoses from the condenser.
(5) Unplug the harness from the low pressure
switch (Fig. 21).
(6) Remove the radiator and condenser as an as-
sembly.
(7) Remove the retaining bolts and separate the
condenser from the radiator.
(8) Remove the receiver/drier from the condenser.
Keep receiver/drier openings plugged at all
times to prevent moisture from entering the re-
ceiver/drier.
INSPECTION
When servicing a condenser for a leak at the bot-
tom, inspect the lower crossmember for an ID tag.
This tag may rub against the condenser. If the con-
dition exists, remove the tag prior to installing a new
condenser.
Fig. 18 Vacuum Motor
Fig. 19 Vacuum Door Motor Cover
Fig. 20 Vacuum Door Motor
JHEATING AND AIR CONDITIONING 24 - 31