1994 JEEP CHEROKEE bolt pattern

BEARING-TO-JOURNAL CLEARANCE (CRANKSHAFT
INSTALLED)
When using Plastigage, check only one bearing
clearance at a time.
Install the grooved main bearings into the cylinder
block and the non-grooved bearings into the bearing
caps.
Install the crankshaft into the upper bearings dry.
Place a strip of Plastigage across full width of the
crankshaft journal to be checked.
Install the bearing cap and tighten the bolts to 108
Nzm (80 ft. lbs.) torque.
DO NOT rotate the crankshaft. This will cause
the Plastigage to shift, resulting in an inaccurate
reading. Plastigage must not be permitted to
crumble. If brittle, obtain fresh stock.
Remove the bearing cap. Determine the amount of
clearance by measuring the width of the compressed
Plastigage with the scale on the Plastigage envelope
(Fig. 5). Refer to Engine Specifications for the proper
clearance.
Plastigage should indicate the same clearance
across the entire width of the insert. If clearance var-
ies, it may indicate a tapered journal or foreign ma-
terial trapped behind the insert.
If the specified clearance is indicated and there are
no abnormal wear patterns, replacement of the bear-
ing inserts is not necessary. Remove the Plastigage
from the crankshaft journal and bearing insert. Pro-
ceed to Crankshaft Main BearingÐInstallation.
If the clearance exceeds specification, install a pair
of 0.025 mm (0.001 inch) undersize bearing inserts
and measure the clearance as described in the previ-
ous steps.
The clearance indicated with the 0.025 mm (0.001
inch) undersize insert pair installed will determine if
this insert size or some other combination will pro-
vide the specified clearance.FOR EXAMPLE:If the clearance was 0.0762 mm
(0.003 inch) originally, a pair of 0.0254 mm (0.001
inch) undersize inserts would reduce the clearance by
0.0254 mm (0.001 inch). The clearance would then be
0.0508 mm (0.002 inch) and within the specification.
A 0.051 mm (0.002 inch) undersize bearing insert
and a 0.0254 mm (0.001 inch) undersize insert would
reduce the original clearance an additional 0.0127
mm (0.0005 inch). The clearance would then be
0.0381 mm (0.0015 inch).
CAUTION: Never use a pair of inserts that differ
more than one bearing size as a pair.
FOR EXAMPLE:DO NOT use a standard size up-
per insert and a 0.051 mm (0.002 inch) undersize
lower insert.
If the clearance exceeds specification using a pair
of 0.051 mm (0.002 inch) undersize bearing inserts,
measure crankshaft journal diameter with a mi-
crometer. If the journal diameter is correct, the
crankshaft bore in the cylinder block may be mis-
aligned, which requires cylinder block replacement
or machining to true bore.
If journals 1 through 5 diameters are less than
63.4517 mm (2.4981 inches), replace crankshaft or
grind crankshaft down to accept the appropriate un-
dersize bearing inserts.
Once the proper clearances have been obtained,
proceed to Crankshaft Main BearingÐInstallation.
MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT
REMOVED)
Remove the crankshaft from the cylinder block (re-
fer to Cylinder Block - Disassemble).
Clean the oil off the main bearing journal.
Determine the maximum diameter of the journal
with a micrometer. Measure at two locations 90É
apart at each end of the journal.
The maximum allowable taper and out of round is
0.013 mm (0.0005 inch). Compare the measured di-
ameter with the journal diameter specification (Main
Bearing Fitting Chart). Select inserts required to ob-
tain the specified bearing-to-journal clearance.
Once the proper clearances have been obtained,
proceed to Crankshaft Main BearingÐInstallation.
INSTALLATION
(1) Lubricate the bearing surface of each insert
with engine oil.
(2) Loosen all the main bearing caps. Install the
main bearing upper inserts.
(3) Install the lower bearing inserts into the main
bearing caps.
(4) Install the main bearing cap(s) and lower in-
sert(s).
(5) Clean the rear main bearing cap (No.5) mating
surfaces.
Fig. 5 Measuring Bearing Clearance with Plastigage
9 - 42 2.5L ENGINEJ

(3) Check for rocker arm bridges which are caus-
ing misalignment of the rocker arm to valve tip area.
(4) Remove the bridges, pivots and corresponding
pairs of rocker arms (Fig. 2). Place them on a bench
in the same order as removed.
(5) Remove the push rods and place them on a
bench in the same order as removed.
CLEANING
Clean all the components with cleaning solvent.
Use compressed air to blow out the oil passages in
the rocker arms and push rods.
INSPECTION
Inspect the pivot surface area of each rocker arm.
Replace any that are scuffed, pitted, cracked or ex-
cessively worn.
Inspect the valve stem tip contact surface of each
rocker arm and replace any rocker arm that is deeply
pitted.
Inspect each push rod end for excessive wear and
replace as required. If any push rod is excessively
worn because of lack of oil, replace it and inspect the
corresponding hydraulic tappet for excessive wear.
Inspect the push rods for straightness by rolling
them on a flat surface or by shining a light between
the push rod and the flat surface.
A wear pattern along the length of the push rod is
not normal. Inspect the engine cylinder head for ob-
struction if this condition exists.
INSTALLATION
(1) Lubricate the ball ends of the push rods with
Mopar Engine Oil Supplement, or equivalent and in-
stall push rods in their original locations. Ensurethat the bottom end of each push rod is centered in
the tappet plunger cap seat.
(2) Using Mopar Engine Oil Supplement, or equiv-
alent, lubricate the area of the rocker arm that the
pivot contacts. Install rocker arms, pivots and bridge
above each cylinder in their originally position.
(3) Loosely install the capscrews through each
bridge.
(4) At each bridge, tighten the capscrews alter-
nately, one turn at a time, to avoid damaging the
bridge. Tighten the capscrews to 28 Nzm (21 ft. lbs.)
torque.
(5) Install the engine cylinder head cover.
ENGINE CYLINDER HEAD
This procedure can be done with the engine in or
out of the vehicle.
REMOVAL
(1) Disconnect negative cable from battery.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drain the coolant and disconnect the hoses at
the engine thermostat housing. DO NOT waste reus-
able coolant. If the solution is clean and is being
drained only to service the engine or cooling system,
drain the coolant into a clean container for reuse.
(3) Remove the air cleaner assembly.
(4) Remove the engine cylinder head cover.
(5) Remove the capscrews, bridge and pivot assem-
blies and rocker arms (Fig. 2).
(6) Remove the push rods (Fig. 2).Retain the
push rods, bridges, pivots and rocker arms in
the same order as removed.
(7) Loosen the serpentine drive belt at the power
steering pump, if equipped or at the idler pulley (re-
fer to Group 7, Cooling System for the proper proce-
dure).
(8) If equipped with air conditioning, perform the
following:
(a) Remove the bolts from the A/C compressor
mounting bracket and set the compressor aside.
(b) Remove the air conditioner compressor
bracket bolts from the engine cylinder head.
(c) Loosen the through bolt at the bottom of the
bracket.
(9) If equipped, disconnect the power steering
pump bracket. Set the pump and bracket aside. DO
NOT disconnect the hoses.
(10) Remove the fuel lines and vacuum advance
hose.
Fig. 2 Rocker Arm Assembly
9 - 60 4.0L ENGINEJ

INSPECTIONÐCONNECTING ROD
CONNECTING ROD BEARINGS
Inspect the connecting rod bearings for scoring and
bent alignment tabs (Figs. 3 and 4). Check the bear-
ings for normal wear patterns, scoring, grooving, fa-
tigue and pitting (Fig. 5). Replace any bearing that
shows abnormal wear.
Inspect the connecting rod journals for signs of
scoring, nicks and burrs.CONNECTING RODS
Misaligned or bent connecting rods can cause ab-
normal wear on pistons, piston rings, cylinder walls,
connecting rod bearings and crankshaft connecting
rod journals. If wear patterns or damage to any of
these components indicate the probability of a mis-
aligned connecting rod, inspect it for correct rod
alignment. Replace misaligned, bent or twisted con-
necting rods.
BEARING-TO-JOURNAL CLEARANCE
(1) Wipe the oil from the connecting rod journal.
(2) Use short rubber hose sections over rod bolts
during installation.
(3) Lubricate the upper bearing insert and install
in connecting rod.
(4) Use piston ring compressor to install the rod
and piston assemblies. The oil squirt holes in the
rods must face the camshaft. The arrow on the piston
crown should point to the front of the engine (Fig. 6).
Verify that the oil squirt holes in the rods face the
camshaft and that the arrows on the pistons face the
front of the engine.
(5) Install the lower bearing insert in the bearing
cap. The lower insert must be dry. Place strip of Plas-
tigage across full width of the lower insert at the cen-
ter of bearing cap. Plastigage must not crumble in
use. If brittle, obtain fresh stock.
(6) Install bearing cap and connecting rod on the
journal and tighten nuts to 45 Nzm (33 ft. lbs.)
torque. DO NOT rotate crankshaft. Plastigage will
smear, resulting in inaccurate indication.
(7) Remove the bearing cap and determine amount
of bearing-to-journal clearance by measuring the
width of compressed Plastigage (Fig. 7). Refer to En-
gine Specifications for the proper clearance.Plasti-
gage should indicate the same clearance across
the entire width of the insert. If the clearance
varies, it may be caused by either a tapered
Fig. 3 Connecting Rod Bearing Inspection
Fig. 4 Locking Tab Inspection
Fig. 5 Scoring Caused by Insufficient Lubrication or
by Damaged Crankshaft Pin Journal
Fig. 6 Rod and Piston Assembly Installation
J4.0L ENGINE 9 - 75

the insert approximately 25 mm (1 inch), it can be
removed by applying pressure under the tab.
(8) Using the same procedure described above, re-
move the remaining bearing inserts one at a time for
inspection.
INSPECTION
Wipe the inserts clean and inspect for abnormal
wear patterns and for metal or other foreign material
imbedded in the lining. Normal main bearing insert
wear patterns are illustrated (Fig. 3).
If any of the crankshaft journals are scored,
remove the engine for crankshaft repair.
Inspect the back of the inserts for fractures, scrap-
ings or irregular wear patterns.
Inspect the upper insert locking tabs for damage.
Replace all damaged or worn bearing inserts.
FITTING (CRANKSHAFT INSTALLED)
The main bearing caps, numbered (front to rear)
from 1 through 7 have an arrow to indicate the for-
ward position. The upper main bearing inserts are
grooved to provide oil channels while the lower in-
serts are smooth.
Each bearing insert pair is selectively fitted to its
respective journal to obtain the specified operating
clearance. In production, the select fit is obtained by
using various-sized color-coded bearing insert pairs
as listed in the Main Bearing Fitting Chart. The
bearing color code appears on the edge of the insert.
The size is not stamped on bearing inserts used
for engine production.
The main bearing journal size (diameter) is identi-
fied by a color-coded paint mark on the adjacent
cheek. The rear main journal, is identified by a color-
coded paint mark on the crankshaft rear flange.
When required, upper and lower bearing inserts of
different sizes may be used as a pair. A standard size
insert is sometimes used in combination with a 0.025
mm (0.001 inch) undersize insert to reduce the clear-
ance by 0.013 mm (0.0005 inch).Never use a pair
of bearing inserts with greater than a 0.025 mm
(0.001 inch) difference in size (Fig. 4).
When replacing inserts, the odd size inserts
must be either all on the top (in cylinder block)
or all on the bottom (in main bearing cap).
Once the bearings have been properly fitted, pro-
ceed to Crankshaft Main BearingÐInstallation.
BEARING-TO-JOURNAL CLEARANCE (CRANKSHAFT
INSTALLED)
When using Plastigage, check only one bearing
clearance at a time.
Install the grooved main bearings into the cylinder
block and the non-grooved bearings into the bearing
caps.
Install the crankshaft into the upper bearings dry.
Place a strip of Plastigage across full width of the
crankshaft journal to be checked.
Install the bearing cap and tighten the bolts to 108
Nzm (80 ft. lbs.) torque.
Fig. 2 Removing Upper Inserts
Fig. 3 Main Bearing Wear Patterns
Fig. 4 Bearing Insert Pairs
J4.0L ENGINE 9 - 81

DO NOT rotate the crankshaft. This will cause
the Plastigage to shift, resulting in an inaccurate
reading. Plastigage must not be permitted to
crumble. If brittle, obtain fresh stock.
Remove the bearing cap. Determine the amount of
clearance by measuring the width of the compressed
Plastigage with the scale on the Plastigage envelope
(Fig. 5). Refer to Engine Specifications for the proper
clearance.
Plastigage should indicate the same clearance
across the entire width of the insert. If clearance var-
ies, it may indicate a tapered journal or foreign ma-
terial trapped behind the insert.
If the specified clearance is indicated and there are
no abnormal wear patterns, replacement of the bear-
ing inserts is not necessary. Remove the Plastigage
from the crankshaft journal and bearing insert. Pro-
ceed to Crankshaft Main BearingÐInstallation.
If the clearance exceeds specification, install a pair
of 0.025 mm (0.001 inch) undersize bearing inserts
and measure the clearance as described in the previ-
ous steps.
The clearance indicated with the 0.025 mm (0.001
inch) undersize insert pair installed will determine if
this insert size or some other combination will pro-
vide the specified clearance.
FOR EXAMPLE:If the clearance was 0.0762 mm
(0.003 inch) originally, a pair of 0.0254 mm (0.001
inch) undersize inserts would reduce the clearance by
0.0254 mm (0.001 inch). The clearance would then be
0.0508 mm (0.002 inch) and within the specification.
A 0.051 mm (0.002 inch) undersize bearing insert
and a 0.0254 mm (0.001 inch) undersize insert would
reduce the original clearance an additional 0.0127
mm (0.0005 inch). The clearance would then be
0.0381 mm (0.0015 inch).
CAUTION: Never use a pair of inserts that differ
more than one bearing size as a pair.FOR EXAMPLE:DO NOT use a standard size up-
per insert and a 0.051 mm (0.002 inch) undersize
lower insert.
If the clearance exceeds specification using a pair
of 0.051 mm (0.002 inch) undersize bearing inserts,
measure crankshaft journal diameter with a mi-
crometer. If the journal diameter is correct, the
crankshaft bore in the cylinder block may be mis-
aligned, which requires cylinder block replacement
or machining to true bore.
Replace the crankshaft or grind to accept the ap-
propriate undersize bearing inserts if:
²Journal diameters 1 through 6 are less than
63.4517 mm (2.4981 inches)
²Journal 7 diameter is less than 63.4365 mm
(2.4975 inches).
Once the proper clearances have been obtained,
proceed to Crankshaft Main BearingÐInstallation.
MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT
REMOVED)
Remove the crankshaft from the cylinder block (re-
fer to Cylinder Block - Disassemble).
Clean the oil off the main bearing journal.
Determine the maximum diameter of the journal
with a micrometer. Measure at two locations 90É
apart at each end of the journal.
The maximum allowable taper and out of round is
0.013 mm (0.0005 inch). Compare the measured di-
ameter with the journal diameter specification (Main
Bearing Fitting Chart). Select inserts required to ob-
tain the specified bearing-to-journal clearance.
Install the crankshaft into the cylinder block (refer
to Cylinder Block - Assemble and Crankshaft Main
Bearings - Installation).
INSTALLATION
(1) Lubricate the bearing surface of each insert
with engine oil.
(2) Loosen all the main bearing caps. Install the
main bearing upper inserts.
(3) Install the lower bearing inserts into the main
bearing caps.
(4) Install the main bearing cap(s) and lower in-
sert(s).
(5) Tighten the bolts of caps 1, 2, 4, 5, 6, and 7 to
54 Nzm (40 ft. lbs.) torque. Now tighten these bolts to
95 Nzm (70 ft. lbs.) torque. Finally, tighten these
bolts to 108 Nzm (80 ft. lbs.) torque.
(6) Push the crankshaft forward and backward.
Load the crankshaft front or rear and tighten cap
bolt No.3 to 54 Nzm (40 ft. lbs.) torque. Then tighten
to 95 Nzm (70 ft. lbs.) torque and finally tighten to
108 Nzm (80 ft. lbs.) torque.
(7) Rotate the crankshaft after tightening each
main bearing cap to ensure the crankshaft rotates
freely.
Fig. 5 Measuring Bearing Clearance with Plastigage
9 - 82 4.0L ENGINEJ

(Fig. 2). The first number is year of manufacture.
The second and third numbers indicate month of
manufacture. The next series of numbers is the
transmission serial number.
GEAR RATIOS
AX 4 and AX 5 gear ratios are as follows:
²First gear: 3.93:1
²Second gear: 2.33:1
²Third gear: 1.45:1
²Fourth gear: 1.00:1
²Fifth gear (AX 5): 0.85:1
²Reverse gear: 4.74:1
SHIFT PATTERN
The AX 4/5 first through fourth gear shift pattern
is in a conventional H configuration. On the AX 5,
fifth gear is up and to the right and reverse gear is
down and to the right (Fig. 3).
RECOMMENDED LUBRICANT
Recommended lubricant for AX 4/5 transmissions
is Mopar 75W-90, API Grade GL-5 gear lubricant, or
equivalent SAE rated gear lubricant.
Correct lubricant fill level is to the bottom edge of
the fill plug hole. The fill plug is at the passenger
side of the adapter housing Fig. 4). The drain plug is
at the bottom of the case.
Approximate dry fill lubricant capacity is 3.3 liters
(3.5 qts.).
SERVICE DIAGNOSIS
LOW LUBRICANT LEVEL
A low transmission lubricant level is generally the
result of a leak, inadequate lubricant fill, or an in-
correct lubricant level check.
Leaks can occur at the mating surfaces of the gear
case, intermediate plate and adaptor or extension
housing, or from the front/rear seals. A suspected
leak could also be the result of an overfill condition.
Leaks at the rear of the extension or adapter hous-
ing will be from the housing oil seals. Leaks at com-
ponent mating surfaces will probably be the result of
inadequate sealer, gaps in the sealer, incorrect bolt
tightening, or use of a non-recommended sealer.
A leak at the front of the transmission will be from
either the front bearing retainer or retainer seal. Lu-
bricant may be seen dripping from the clutch hous-
ing after extended operation. If the leak is severe, it
may also contaminate the clutch disc causing slip,
grab and chatter.
Transmissions filled from air or electrically pow-
ered lubricant containers can be underfilled. This
generally happens when the container delivery mech-
anism is improperly calibrated. Always check the lu-
bricant level after filling to avoid an under fill
condition.
Fig. 2 Transmission Identification
Fig. 3 Shift PatternÐAX 4/5 Transmission
Fig. 4 Fill Plug Location
21 - 2 AX 4/5 MANUAL TRANSMISSIONJ

TRANSMISSION SHIFT PATTERN
The AX 15 shift pattern is shown in Figure 3. First
and second and third and fourth gear ranges are in
line for improved shifting. Fifth and reverse gear
ranges are also in line at the extreme right of the
pattern (Fig. 3).
The AX 15 is equipped with a reverse lockout
mechanism. The shift lever must be moved through
the Neutral detent before making a shift to reverse.
TRANSMISSION LUBRICANT
Recommended lubricant for AX 15 transmissions is
Mopar 75W-90, API Grade GL-5 gear lubricant, or
equivalent.
Correct lubricant refill or top-off level is to the bot-
tom edge of the fill plug hole.
Lubricant capacity is:
²3.10 liters (3.27 qts.) in 4-wheel drive models.
²3.15 liters (3.32 qts.) in 2-wheel drive models.
TRANSMISSION SWITCH AND PLUG LOCATIONS
The fill plug is at the driver side of the gear case
(Fig. 4).
The drain plug and backup light switch are on the
passenger side of the gear case (Fig. 5).
TRANSMISSION GEAR RATIOS
The transmission gear ratios are as follows:
First gear - 3.83:1
Second gear - 2.33:1
Third gear - 1.44:1
Fourth gear - 1.00:1
Fifth gear - 0.79:1
Reverse - 4.22:1
SERVICE DIAGNOSIS
LOW LUBRICANT LEVEL
A low transmission lubricant level is generally the
result of a leak, inadequate lubricant fill, or an in-
correct lubricant level check.
Leaks can occur at the mating surfaces of the gear
case, intermediate plate and adapter or extension
housing, or from the front/rear seals. A suspected
leak could also be the result of an overfill condition.
Leaks at the rear of the extension or adapter hous-
ing will be from the housing oil seals. Leaks at com-
ponent mating surfaces will probably be the result of
inadequate sealer, gaps in the sealer, incorrect bolt
tightening, or use of a non-recommended sealer.
A leak at the front of the transmission will be from
either the front bearing retainer or retainer seal. Lu-
bricant may be seen dripping from the clutch hous-
ing after extended operation. If the leak is severe, it
may also contaminate the clutch disc causing slip,
grab and chatter.
Transmissions filled from air or electrically pow-
ered lubricant containers can be underfilled. This
generally happens when the container delivery mech-
anism is improperly calibrated. Always check the lu-
bricant level after filling to avoid an under fill
condition.
A correct lubricant level check can only be made
when the vehicle is level; use a drive-on hoist to en-
sure this. Also allow the lubricant to settle for a
Fig. 3 AX 15 Shift Pattern
Fig. 4 Fill Plug Location
Fig. 5 Drain Plug And Backup Light Switch Location
JAX 15 MANUAL TRANSMISSION 21 - 33

VALVE BODY INSTALLATION
(1) Place valve body manual lever in low (1 posi-
tion) so park lock rod can be installed in sprag.
(2) Position park sprag with screwdriver to ease
lock rod installation and engagement.
(3) Install new seals on accumulator piston if nec-
essary and install piston in case. A small amount of
petroleum jelly can be used to hold piston in place.
(4) Lubricate shaft of manual lever and lip of shaft
seal with petroleum jelly.
(5) Raise valve body and align park rod with case
opening and park sprag. Then push rod end through
opening and past sprag. Rotate propeller shaft if nec-
essary.
(6) Position accumulator spring on transfer plate.
(7) Align valve body and seat it on case. Be sure
manual lever shaft and accumulator spring are prop-
erly seated.
(8) Hold valve body in position and install one or
two attaching bolts to hold valve body in place.
(9) Install remaining valve body bolts. Tighten all
bolts evenly in a diagonal pattern to 12 Nzm (105 in-
lbs) torque.
(10) Install new oil filter and tighten filter screws
to4Nzm (35 in. lbs.) torque.
(11) Connect converter solenoid wire to case con-
nector.
(12) Install manual and throttle levers on throttle
lever shaft. Tighten lever clamp screws and check for
free operation. Shaft and levers must operate freely
without any bind.
(13) Install oil pan and new gasket. Tighten pan
bolts to 17 Nzm (13 ft. lbs.) torque.
(14) Install seal on neutral switch, install switch in
case, and connect switch wires.(15) Lower vehicle.
(16) Fill transmission with Mopar ATF Plus, Type
7176 fluid.
(17) Adjust gearshift linkage and throttle valve
(kickdown) cable if necessary.
GOVERNOR AND PARK GEAR SERVICE
GOVERNOR REMOVAL
(1) Raise vehicle.
(2) Mark both propeller shaft yokes for assembly
reference and disconnect propeller shafts at transfer
case.
(3) Disconnect speedometer cable.
(4) Position support stand under transmission con-
verter housing.
(5) Remove rear crossmember.
(6) Disconnect parking brake cable at equalizer
and disconnect exhaust pipe support brackets, if nec-
essary.
(7) Support transfer case with jack.
(8) Remove bolts attaching transfer case to trans-
mission adapter housing and remove transfer case.
(9) Remove bolts attaching adapter, or extension
housing to transmission and remove housing.
(10) Rotate transmission output shaft until gover-
nor valve shaft E-clip faces downward (Fig. 12).
(11) Remove E-clip from one end of governor valve
shaft (Fig. 12).
(12) Remove governor valve and shaft from gover-
nor body.
(13) Remove snap ring that retains governor body-
park gear assembly on output shaft (Fig. 12).
(14) Remove governor body-park gear assembly
from output shaft.
Fig. 12 Governor E-clips And Attaching Bolts
Fig. 11 Valve Body Assembly
J30RH/32RH IN-VEHICLE SERVICE 21 - 101