1994 JEEP CHEROKEE seats

INSTALLATIONÐYJ MODELS
(1) Place tank into skid plate. Wrap straps around
tank with strap bolts inserted through holes in skid
plate. Tighten strap nuts to 7.3 Nzm (65 in. lbs.) torque.
(2) Raise skid plate/fuel tank until gauge sender wire
connector can be connected to harness connector.
(3) Finish raising skid plate/fuel tank assembly
into position. Tighten mounting nuts to 16 Nzm (12
ft. lbs.) torque. Remove transmission jack.
(4) Connect fuel fill hose and fill vent hose to filler
neck. Tighten hose clamps.
(5) Connect vent hose to vent tube.
(6) Connect fuel supply hose to the supply tube and
fuel return hose to return tube. Tighten hose clamps.
(7) Install fuel filler neck shroud with push clips.
(8) Lower vehicle.
(9) Fill fuel tank. Install filler cap.
(10) Connect negative battery cable to battery.
(11) Start vehicle and inspect for leaks.
FUEL GAUGE SENDING UNIT
The fuel gauge sending unit is attached to the fuel
pump module. Refer to Fuel Pump Module in the
Fuel Delivery System section of this group.
FUEL TANK PRESSURE RELIEF/ROLLOVER VALVE
The fuel tank is equipped with a pressure relief/
rollover valve (Fig. 8). The dual function valve will
relieve fuel tank pressure and prevent fuel flow
through the fuel tank vent tubes in the event of ac-
cidental vehicle rollover.
The valve consists of a plunger, spring and orifice/
guide plate (Fig. 9). The valve is normally open allowing
fuel vapor to vent to the EVAP canister. Here it is
stored until it can be consumed by the engine (undercontrolled conditions). The plunger seats in the guide
plate at the orifice preventing liquid fuel from reaching
the EVAP canister. This is done if bottom of plunger is
contacted by fuel sloshing in tank when vehicle is cor-
nering.
In the event of accidental vehicle rollover, the valve
is inverted. In this position the plunger is forced
against the guide plate and raw fuel is prevented
from flowing through the valve orifice into the fuel
tank vent tube.
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING THE PRESSURE RELIEF/
ROLLOVER VALVE, THE FUEL SYSTEM PRESSURE
MUST BE RELEASED. REFER TO THE FUEL PRES-
SURE RELEASE PROCEDURE IN THIS GROUP.
(1) Disconnect negative battery cable.
(2) Remove the fuel filler cap and drain fuel tank.
Refer to Fuel Tank Removal.
(3) Remove fuel tank. Refer to Fuel Tank Removal.
(4) The rollover valve is seated in a grommet. Re-
move by prying one side upward and then roll the
grommet out of tank (Fig. 8).
INSTALLATION
(1) Start one side of grommet into opening in fuel
tank. Using finger pressure only, press valve/grom-
met into place.
(2) Install fuel tank. Refer to Fuel Tank Installation.
(3) Fill fuel tank. Install fuel tank filler cap.
(4) Connect negative battery cable.
(5) Start vehicle and check for leaks.
Fig. 8 Valve LocationÐTypical
Fig. 9 Pressure Relief/Rollover Valve Operation
JFUEL SYSTEM 14 - 15

PITMAN SHAFT AND SIDE COVER REPLACEMENT
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
(2) Remove pitman arm from steering gear. Refer
to Pitman Arm Removal in the Steering Linkage sec-
tion.
(3) Rotate stub shaft back and forth to drain power
steering fluid.
DISASSEMBLE
²Clean exposed end of pitman shaft and housing.
²Clean pitman shaft spline with a wire brush.
(1) Remove preload adjuster nut.
(2) Rotate stub shaft with socket to center gear.
Remove side cover bolts.
(3) Remove side cover, gasket and pitman shaft as
an assembly.
(4) Remove pitman shaft from the side cover (Fig.
15).
ASSEMBLE
(1) Install pitman shaft to side cover by screwing
shaft in until it fully seats to side cover.
(2) Install preload adjuster nut.Do not tighten
nut until after pitman shaft adjustment has
been made.(3) Install gasket to side cover and bend tabs
around edges of side cover.
(4) Install pitman shaft assembly and side cover to
housing.
(5) Install side cover bolts and tighten to 60 Nzm
(44 ft. lbs.).
(6) Adjust pitman shaft, refer to Over-Center Ad-
justment.
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
(2) Install pitman arm onto steering gear. Refer to
Steering Linkage in this Group.
HOUSING END PLUG
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
(2) Remove pitman arm from steering gear. Refer
to Steering Linkage in this Group.
(3) Rotate stub shaft back and forth to drain power
steering fluid.
DISASSEMBLE
²Rotate stub shaft back and forth to drain fluid
(1) Rotate retaining ring until one end is under the
hole in the housing. Unseat and force ring from
groove (Fig. 16).
(2) Rotate stub shaft slowly COUNTER-CLOCK-
WISE to remove end plug out from housing (Fig. 17).
Fig. 16 End Plug Retaining Ring
Fig. 15 Side Cover and Pitman Shaft
19 - 26 STEERINGJ

Fitting And Cooler Line Service
The cooler lines and quick disconnect fittings are
NOT serviceable. Damaged fittings or cooler lines
are to be replaced as assemblies.
Fittings swedged into cooler line hoses (Fig. 25) are
serviced only as part of the entire cooler line.
DISCONNECTING COOLER LINES WITH
QUICK DISCONNECT FITTINGS
(1) If fitting and cooler line are encrusted with
dirt, mud, or grease, clean fitting and cooler line
with Mopar spray type carburetor or brake cleaner.
Plastic release tool will not fit into retainer clip if fit-
ting is full of foreign material.
(2) Slide small plastic release tool into fitting until
tool bottoms against flange on cooler line (Fig. 26).
(3) Push and turn tool to spread retainer clip and
pull cooler line out of fitting (Fig. 26).
(4) Cover open ends of cooler lines and fittings to
prevent dirt entry.
(5) Inspect condition of fitting. Replace transmis-
sion fitting as an assembly if fitting body or retainer
clip is damaged. Replace cooler line as assembly, if
fitting swedged into cooler line hose, is damaged.
REATTACHING COOLER LINES WITH QUICK
DISCONNECT FITTINGS
(1) If transmission or radiator fittings require re-
placement, apply Mopar Lock N' Seal, or Loctite 242
to fitting threads before installation.
(2) Wipe off cooler line and fitting with clean, dry
cloth.
(3) Insert cooler line into fitting. Then push line
inward until retainer clip secures line. A snap or
click sound will be heard and felt through the line
when the retainer clip seats behind the cooler line
flange.
(4)Pull outward on cooler lines to verify that
they are properly secured.
CAUTION: The wire retainer clips must secure the
cooler lines in the fittings. If the clips are deformed, or
distorted, normal fluid pressure could unseat the cooler
lines resulting in fluid loss and transmission damage.
Be very sure the cooler lines are firmly secured by the
retainer clip as described in step (4) above.
Fig. 23 Type 2 Quick Disconnect fitting
Fig. 24 Type 3 Quick Disconnect fitting
Fig. 25 Transmission And Cooler Line Fitting Placement
Fig. 26 Disconnecting Cooler Line With Release
Tool (Type 2 Fitting Shown)
J30RH/32RH IN-VEHICLE SERVICE 21 - 107

VALVE BODY ASSEMBLY AND ADJUSTMENT
CAUTION: Do not force valves or plugs into place
during reassembly. If the valve body bores, valves
and plugs are free of distortion or burrs, the valve
body components should all slide into place easily.
In addition, do not overtighten the transfer plate
and valve body screws during reassembly. Over-
tightening can distort the valve body resulting in
valve sticking, cross leakage and unsatisfactory op-
eration. Tighten valve body screws to recom-
mended torque only.
(1) Lubricate valve body bores, valves and plugs
with ATF Plus, or Dexron IIŸ transmission fluid.
(2) Insert rear clutch and rear servo check balls in
transfer plate (Fig. 110).
(3) Install filter screen in separator plate (Fig.
110).
(4) Align and install separator plate on transfer
plate. Verify check ball position before installing sep-
arator plate on transfer plate.
(5) Install new O-ring on converter clutch solenoid
and insert solenoid in separator plate (Fig. 115).
Then secure solenoid in position with attaching
screw. Tighten screw to 4 Nzm 35 in. lbs.) torque.
(6) Position valve body so internal passages and
check ball seats are facing upward. Then install
steel/plastic check balls in valve body (Fig. 116). The
one large check ball is approximately 11/32 inch in
diameter. The remaining check balls are approxi-
mately 1/4 inch in diameter.
(7) Align and install assembled transfer and sepa-
rator plates on valve body. Install and tighten valve
body screws alternately in a diagonal pattern to 4
Nzm (35 in. lbs.) torque.
(8) Assemble and install clutch module and compo-
nents on valve body (Fig. 117).
(9) Assemble regulator valve line pressure plug,
sleeve, throttle plug and spring (Fig. 108). Insert as-
sembly in valve body and install end plate. Tighten
end plate screws to 4 Nzm (35 in. lbs.) torque.
(10) Install 1-2 and 2-3 shift valves and springs
(Fig. 113).(11) Install 1-2 shift control valve and spring (Fig.
113)
(12) Install shuttle valve as follows:
(a) Insert shuttle valve in bore.
(b) Insert plastic guides in shuttle valve second-
ary spring.
(c) Install spring on end of valve.
(d) Hold shuttle valve in place. Then compress
secondary spring and install E-clip in groove at end
of valve.
(e) Verify that spring and E-clip are properly
seated before proceeding.
(13) Install shuttle valve cover plate (Fig. 113).
Tighten end plate screws to 4 Nzm (35 in. lbs.)
torque.
(14) Install 1-2 and 2-3 valve governor plugs in
valve body (Fig. 113). Then install shuttle valve pri-
mary spring and throttle plug.
(15) Align and install governor plug end plate on
valve body and install end plate screws. Tighten
screws to 4 Nzm (35 in. lbs.) torque.
(16) Install manual valve (Fig. 112).
(17) Install throttle valve and spring. Then install
kickdown valve and detent (Fig. 112).
(18) Install pressure regulator valve and switch
valve in valve body.
(19) Install manual lever detent spring in housing.
Place detent ball on end of spring and push ball and
spring into housing. Secure ball and spring with De-
tent Retainer 6583 (Fig. 103).
(20) Insert line pressure adjusting screw in adjust-
ing screw bracket (Fig. 102).
Fig. 116 Correct Position Of Valve Body Check Balls
Fig. 115 Installing Converter Clutch Solenoid
21 - 144 30RH/32RH TRANSMISSION OVERHAULJ

(5) Lubricate and install new O-ring on clutch
drum hub (Fig. 7).
(6) Lubricate and install new O-rings on clutch pis-
ton and install piston in drum.
(7) Install piston return springs.
(8) Compress piston return springs with Tool 7538 and
shop press and install piston snap ring. Be sure snap
ring end gap is not aligned with any notches in drum.
(9) Install cushion plate in drum. Concave side of
plate faces downward (Fig. 5).
(10) Install clutch discs, plates and retainer (Fig. 15). In-
stall tabbed plate followed by disc until required number of
plates and discs are installed. Use six plates and discs.
(11) Install clutch pack snap ring.
(12) Recheck clutch piston stroke length using
same method outlined at beginning of disassembly
procedure. If stroke length is not within specified
limits, replace clutch discs.
(13) Lubricate race and bearing with petroleum jelly
and install them in clutch drum (Fig. 16). Be sure bear-
ing rollers face up and race lip seats in drum as shown.
(14) Verify bearing and race size.
²Outer diameter of bearing is 46.7 mm (1.839 in).
²Outer diameter of race is 48.9 mm (1.925 in.).
²Inner diameter of bearing and race is 26.0 mm
(1.024 in.).
(15) Mount forward clutch on direct clutch and
check assembled height (Fig. 17). Height should be
70.3 - 71.5 mm (2.767 - 2.815 in.).
Fig. 15 Installing Forward Clutch Discs And Plates
Fig. 16 Installing Thrust Bearing And Race
Fig. 17 Checking Forward Clutch Assembled Height
Fig. 14 Installing Clutch Drum Shaft Seal Rings
JAW-4 TRANSMISSION OVERHAUL 21 - 227

(8) Install snap ring on new input gear bearing
and start bearing in case.
(9) Carefully press input gear bearing into case un-
til bearing snap ring seats against case (Fig. 32).
(10) Remove mainshaft pilot bearing from input
gear with Tool MD-998346 and two suitable size open
end wrenches (Fig. 33).(11) Install new pilot bearing in input gear with
shop press, Tool Handle C-4171 and Installer 5065
(Fig. 34).
Fig. 29 Removing/Installing Front Output Shaft
Bearing Snap Ring
Fig. 30 Installing Output Shaft Front Bearing
Fig. 31 Removing Input Gear Bearing
Fig. 32 Input Gear Bearing Installation
Fig. 33 Removing Mainshaft Pilot Bearing From
Input Gear
Fig. 34 Installing Mainshaft Pilot Bearing In Input
Gear
JNP231 TRANSFER CASE 21 - 283

Radial runout of more than 1.5 mm (.060 inch)
measured at the center line of the tread may cause
the vehicle to shake.
Lateral runout of more than 2.0 mm (.080 inch)
measured near the shoulder of the tire may cause the
vehicle to shake.
Sometimes radial runout can be reduced. Relocate
the wheel and tire assembly on the mounting studs
(See Method 1). If this does not reduce runout to an
acceptable level, the tire can be rotated on the wheel.
(See Method 2).
METHOD 1 (RELOCATE WHEEL ON HUB)
Check accuracy of the wheel mounting surface; ad-
just wheel bearings.
Drive vehicle a short distance to eliminate tire flat
spotting from a parked position.
Make sure all wheel nuts are properly torqued.
Relocate wheel on the mounting, two studs over
from the original position.
Re-tighten wheel nuts until all are properly
torqued, to eliminate brake distortion.
Check radial runout. If still excessive, mark tire
sidewall, wheel, and stud at point of maximum
runout and proceed to Method 2.
METHOD 2 (RELOCATE TIRE ON WHEEL)
Rotating tire on wheel is particularly effective
when there is runout in both tire and wheel.Remove tire from wheel and re-mount wheel on
hub in former position.
Check wheel radial runout (Fig. 9).
²STEEL WHEELS: Radial runout 0.040 in., Lateral
runout 0.045 in.
²ALUMINUM WHEELS: Radial runout 0.030 in.,
Lateral runout 0.035 in.
If point of greatest runout is near original chalk
mark, remount tire 180 degrees. Recheck runout.
VEHICLE VIBRATION
Vehicle vibration can be caused by:
²Tire/wheel unbalance or excessive runout
²Defective tires with extreme tread wear
²Nylon overlay flat spots (performance tires only)
²Incorrect wheel bearing adjustment (if applicable)
²Loose or worn suspension/steering components
²Certain tire tread patterns
²Incorrect drive shaft angles or excessive drive
shaft/yoke runout
²Defective or worn U-joints
²Excessive brake rotor or drum runout
²Loose engine or transmission supports/mounts
²And by engine operated accessories
Refer to the appropriate Groups in this man-
ual for additional information.
VIBRATION TYPES
There are two types of vehicle vibration:
²Mechanical
²Audible.
Mechanical vehicle vibration can be felt through
the seats, floor pan and/or steering wheel.
Audible vehicle vibration is heard above normal
background noise. The sound can be a droning or
drumming noise.Vibrations are sensitive to change in engine
torque, vehicle speed or engine speed.
ENGINE TORQUE SENSITIVE VIBRATION
This vibration can be increased or decreased by:
²Accelerating
²Decelerating
²Coasting
²Maintaining a constant vehicle speed
VEHICLE SPEED SENSITIVE VIBRATION
This vibration condition always occurs at the same
vehicle speed regardless of the engine torque or en-
gine speed.
ENGINE SPEED (RPM) SENSITIVE VIBRATION
This vibration occurs at varying engine speeds. It
can be isolated by increasing or decreasing the en-
gine speed with the transmission in NEUTRAL posi-
tion.
VIBRATION DIAGNOSIS
A vibration diagnosis should always begin with a
10 mile (16 km) trip (to warm the vehicle and tires).
Then a road test to identify the vibration. Corrective
Fig. 9 Checking Wheel Runout
JWHEELS AND TIRES 22 - 9

INTERIOR COMPONENTS
INDEX
page page
Assist HandleÐXJ Vehicles................ 118
B/C-Pillar and Liftgate Pillar Trim CoversÐ
XJ Vehicles.......................... 116
Bucket Seat Cushion and Cover............. 98
Bucket Seat Platform and Tracks........... 105
Bucket Seatback Cover and Frame.......... 100
Bucket Seatback Reconditioning............ 102
Carpets and Floor Mats................... 129
Dash Panel Insulation Panel................ 95
Front Bucket Seats....................... 97
Front Carpet/MatÐXJ Vehicles............. 129
Front Inner Scuff Plate/Cowl Side Trim PanelÐ
XJ Vehicles.......................... 114
Front Shoulder Belt/BuckleÐXJ Vehicles...... 119
Full Floor ConsoleÐXJ Vehicles............ 125
Headliner.............................. 121
I/P Ash Receiver Tray Lamp................ 92
I/P Tweeter Speaker/Courtesy Lamp Support
Bracket.............................. 95
Instrument Cluster Bezel................... 91
Instrument Cluster/Switch/Lighter/Radio/Hevac . . . 91
Instrument Panel......................... 93
Interior Trim Panels and Scuff PlatesÐXJ Vehicles. 112
Jack StorageÐXJ Vehicles................ 127
Mini-Floor ConsoleÐXJ Vehicles............ 124
Outer Scuff PlatesÐXJ Vehicles............ 118
Power Bucket Seat Components............ 106
Quarter and Wheelhouse Trim PanelsÐ
XJ Vehicles.......................... 115
Quarter Trim Panel ExtensionÐXJ Vehicles . . . 115
Rear Carpet/MatÐXJ Vehicles.............. 130
Rear Seat Cushion CoverÐXJ Vehicles...... 107
Rear Seat Cushion ReconditioningÐXJ Vehicles . 108
Rear Seat CushionÐXJ Vehicles............ 107
Rear Seatback CoverÐXJ Vehicles.......... 111
Rear Seatback Latch Striker and BumperÐ
XJ Vehicles.......................... 111
Rear Seatback ReconditioningÐXJ Vehicles . . . 111
Rear SeatbackÐXJ Vehicles............... 109
Rear Shoulder/Lap Belt/BuckleÐXJ Vehicles . . . 120
Spare Tire/Wheel Holddown and Floor BracketsÐ
XJ Vehicles.......................... 128
Sunvisors............................. 124
Windshield Side MouldingÐXJ Vehicles...... 114
INSTRUMENT CLUSTER BEZEL
REMOVAL
(1) Remove the bezel retaining screws (Fig. 1).
(2) Separate the bezel from the U-clips and remove
it from the upper section of the instrument panel.
(3) If necessary, remove or install rocker switch
cover plates (Fig. 2).
INSTALLATION
(1) Position the bezel on the upper instrument
panel and engage it with the U-clips.
(2) Install the bezel retaining screws. Tighten the
screws with 1 Nzm (11 in-lbs) torque.
INSTRUMENT CLUSTER/SWITCH/LIGHTER/RADIO/
HEVAC
REMOVAL
(1) Remove the screws and instrument cluster be-
zel from instrument panel (Fig. 3).
(2) As applicable, remove the instrument cluster or
other I/P component screws.
(3) Disconnect wire harness connector(s) from cluster
or other I/P component. Refer to Group 8ÐElectrical.
(4) Remove the cluster or other I/P component
from the upper section of instrument panel (Fig. 9).
Fig. 1 Instrument Cluster Bezel Removal/Installation
Fig. 2 Instrument Cluster Bezel Removal/Installation
JBODY COMPONENTSÐXJ VEHICLES 23 - 91